Golf club heads and methods to manufacture golf club heads

ABSTRACT

Embodiments of golf club heads and methods to manufacture golf club heads are generally described herein. In one example, a golf club head may include a body portion with a toe portion, a heel portion, a top portion, a sole portion, a back portion, and a front portion having a face portion. The golf club head may include an interior cavity. The interior cavity is at least partially filled with an elastic polymer material. A bonding portion bonds the elastic polymer material to the face portion. Other examples and embodiments may be described and claimed.

CROSS REFERENCE

This application claims the benefit of U.S. Provisional Application No.62/118,403, filed on Feb. 19, 2015, U.S. Provisional Application No.62/159,856, filed on May 11, 2015, U.S. Provisional Application No.62/209,780, filed on Aug. 25, 2015, U.S. Provisional Application No.62/275,443, filed on Jan. 6, 2016, U.S. Provisional Application No.62/276,358, filed on Jan. 8, 2016, and U.S. Provisional Application No.62/277,636, filed on Jan. 12, 2016. This application is acontinuation-in-part application of U.S. Non-Provisional applicationSer. No. 14/589,277, filed on Jan. 5, 2015, which is a continuationapplication of U.S. Non-Provisional application Ser. No. 14/498,603,filed on Sep. 26, 2014, which claims the benefit of U.S. ProvisionalApplication No. 62/041,538 filed Aug. 25, 2014. This application is alsoa continuation-in-part application of U.S. Non-Provisional applicationSer. No. 14/711,596, filed May 13, 2015, which is a continuation-in-partapplication of U.S. Non-Provisional application Ser. No. 14/589,277,filed Jan. 5, 2015, which is a continuation application of U.S.Non-Provisional application Ser. No. 14/513,073, filed Oct. 13, 2014,which is a continuation application of U.S. Non-Provisional applicationSer. No. 14/498,603, filed Sep. 26, 2014, which claims the benefit ofU.S. Provisional Application No. 62/041,538, filed Aug. 25, 2014. Thisapplication is also a continuation-in-part application of U.S.application Ser. No. 29/515,013, filed on Jan. 20, 2015, which is acontinuation-in-part application of U.S. application Ser. No.29/501,006, filed on Aug. 29, 2014. This application is also acontinuation-in-part application of U.S. application Ser. No.29/547,678, filed on Dec. 7, 2015, which is a continuation-in-partapplication of U.S. application Ser. No. 29/540,066, filed on Sep. 21,2015, which is a continuation-in-part application of U.S. applicationSer. No. 29/537,413, filed on Aug. 25, 2015. The disclosure of thereferenced applications are incorporated herein by reference.

COPYRIGHT AUTHORIZATION

The present disclosure may be subject to copyright protection. Thecopyright owner has no objection to the facsimile reproduction by anyoneof the present disclosure and its related documents, as they appear inthe Patent and Trademark Office patent files or records, but otherwisereserves all applicable copyrights.

FIELD

The present disclosure generally relates to golf equipment, and moreparticularly, to golf club heads and methods to manufacturing golf clubheads.

BACKGROUND

Various materials (e.g., steel-based materials, titanium-basedmaterials, tungsten-based materials, etc.) may be used to manufacturegolf club heads. By using multiple materials to manufacture golf clubheads, the position of the center of gravity (CG) and/or the moment ofinertia (MOI) of the golf club heads may be optimized to produce certaintrajectory and spin rate of a golf ball.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a front view of a golf club head according to anembodiment of the apparatus, methods, and articles of manufacturedescribed herein.

FIG. 2 depicts a rear view of the example golf club head of FIG. 1.

FIG. 3 depicts a top view of the example golf club head of FIG. 1.

FIG. 4 depicts a bottom view of the example golf club head of FIG. 1.

FIG. 5 depicts a left view of the example golf club head of FIG. 1.

FIG. 6 depicts a right view of the example golf club head of FIG. 1.

FIG. 7 depicts a cross-sectional view of the example golf club head ofFIG. 1 along line 7-7.

FIG. 8 depicts a cross-sectional view of the example golf club head ofFIG. 1 along line 8-8.

FIG. 9 depicts a cross-sectional view of the example golf club head ofFIG. 1 along line 9-9.

FIG. 10 depicts another rear view of the example golf club head of FIG.1.

FIG. 11 depicts a top view of a weight portion associated with theexample golf club head of FIG. 1.

FIG. 12 depicts a side view of a weight portion associated with theexample golf club head of FIG. 1.

FIG. 13 depicts a side view of another weight portion associated withthe example golf club head of FIG. 1.

FIG. 14 depicts a rear view of a body portion of the example golf clubhead of FIG. 1.

FIG. 15 depicts a cross-sectional view of a face portion of the examplegolf club head of FIG. 1.

FIG. 16 depicts a cross-sectional view of another face portion of theexample golf club head of FIG. 1.

FIG. 17 depicts one manner in which the example golf club head describedherein may be manufactured.

FIG. 18 depicts another cross-sectional view of the example golf clubhead of FIG. 4 along line 18-18.

FIG. 19 depicts a front view of a face portion of the example golf clubhead of FIG. 1.

FIG. 20 depicts a back view of the face portion of FIG. 19.

FIG. 21 depicts a cross-sectional view of an example channel of the faceportion of FIG. 19.

FIG. 22 depicts a cross-sectional view of another example channel of theface portion of FIG. 19.

FIG. 23 depicts a cross-sectional view of yet another example channel ofthe face portion of FIG. 19.

FIG. 24 depicts a cross-sectional view of yet another example channel ofthe face portion of FIG. 19.

FIG. 25 depicts a back view of another example face portion of theexample golf club head of FIG. 1.

FIG. 26 depicts a back view of yet another example face portion of theexample golf club head of FIG. 1.

FIG. 27 depicts a back view of yet another example face portion of theexample golf club head of FIG. 1.

FIG. 28 depicts a cross-sectional view of the example golf club head ofFIG. 1.

FIG. 29 depicts another manner in which an example golf club headdescribed herein may be manufactured.

FIG. 30 depicts yet another manner in which an example golf club headdescribed herein may be manufactured.

FIG. 31 depicts a rear view of a golf club head according to anembodiment of the apparatus, methods, and articles of manufacturedescribed herein.

FIG. 32 depicts a rear view of the golf club head of FIG. 31.

FIG. 33 depicts a front view of a golf club head according to anembodiment of the apparatus, methods, and articles of manufacturedescribed herein.

FIG. 34 depicts a rear view of the example golf club head of FIG. 33.

FIG. 35 depicts a rear perspective view of the example golf club head ofFIG. 33.

FIG. 36 depicts a rear view of the example golf club head of FIG. 33.

FIG. 37 depicts a cross-sectional view of the example golf club head ofFIG. 33 along line 37-37 of FIG. 36.

FIG. 38 depicts a cross-sectional view of the example golf club head ofFIG. 33 along line 38-38 of FIG. 36.

FIG. 39 depicts a cross-sectional view of the example golf club head ofFIG. 33 along line 39-39 of FIG. 36.

FIG. 40 depicts a cross-sectional view of the example golf club head ofFIG. 33 along line 40-40 of FIG. 36.

FIG. 41 depicts a cross-sectional view of the example golf club head ofFIG. 33 along line 41-41 of FIG. 36.

FIG. 42 depicts a cross-sectional view of the example golf club head ofFIG. 33 along line 42-42 of FIG. 36.

FIG. 43 depicts yet another manner in which an example golf club headdescribed herein may be manufactured.

FIG. 44 depicts yet another manner in which an example golf club headdescribed herein may be manufactured.

FIG. 45 depicts an example of curing a bonding agent.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the present disclosure. Additionally, elementsin the drawing figures may not be depicted to scale. For example, thedimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help improve understanding of embodimentsof the present disclosure.

DESCRIPTION

In general, golf club heads and methods to manufacture golf club headsare described herein. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

In the example of FIGS. 1-14, a golf club head 100 may include a bodyportion 110 (FIG. 14), and two or more weight portions, generally shownas a first set of weight portions 120 (e.g., shown as weight portions121, 122, 123, and 124) and a second set of weight portions 130 (e.g.,shown as weight portions 131, 132, 133, 134, 135, 136, and 137). Thebody portion 110 may include a toe portion 140, a heel portion 150, afront portion 160, a back portion 170, a top portion 180, and a soleportion 190. The body portion 110 may be made of a first materialwhereas the first and second sets of weight portions 120 and 130,respectively, may be made of a second material. The first and secondmaterials may be similar or different materials. For example, the bodyportion 110 may be partially or entirely made of a steel-based material(e.g., 17-4 PH stainless steel, Nitronic® 50 stainless steel, maragingsteel or other types of stainless steel), a titanium-based material, analuminum-based material (e.g., a high-strength aluminum alloy or acomposite aluminum alloy coated with a high-strength alloy), anycombination thereof, and/or other suitable types of materials. The firstand second sets of weight portions 120 and 130, respectively, may bepartially or entirely made of a high-density material such as atungsten-based material or other suitable types of materials.Alternatively, the body portion 110 and/or the first and second sets ofweight portions 120 and 130, respectively, may be partially or entirelymade of a non-metal material (e.g., composite, plastic, etc.). Theapparatus, methods, and articles of manufacture are not limited in thisregard.

The golf club head 100 may be an iron-type golf club head (e.g., a1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron, a 7-iron, an8-iron, a 9-iron, etc.) or a wedge-type golf club head (e.g., a pitchingwedge, a lob wedge, a sand wedge, an n-degree wedge such as 44 degrees(°), 48°, 52°, 56°, 60°, etc.). Although FIGS. 1-10 may depict aparticular type of club head, the apparatus, methods, and articles ofmanufacture described herein may be applicable to other types of clubheads (e.g., a driver-type club head, a fairway wood-type club head, ahybrid-type club head, a putter-type club head, etc.). The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

The toe portion 140 and the heel portion 150 may be on opposite ends ofthe body portion 110. The heel portion 150 may include a hosel portion155 configured to receive a shaft (not shown) with a grip (not shown) onone end and the golf club head 100 on the opposite end of the shaft toform a golf club.

The front portion 160 may include a face portion 162 (e.g., a strikeface). The face portion 162 may include a front surface 164 and a backsurface 166. The front surface 164 may include one or more grooves 168extending between the toe portion 140 and the heel portion 150. Whilethe figures may depict a particular number of grooves, the apparatus,methods, and articles of manufacture described herein may include moreor less grooves. The face portion 162 may be used to impact a golf ball(not shown). The face portion 162 may be an integral portion of the bodyportion 110. Alternatively, the face portion 162 may be a separate pieceor an insert coupled to the body portion 110 via various manufacturingmethods and/or processes (e.g., a bonding process such as adhesive, awelding process such as laser welding, a brazing process, a solderingprocess, a fusing process, a mechanical locking or connecting method,any combination thereof, or other suitable types of manufacturingmethods and/or processes). The face portion 162 may be associated with aloft plane that defines the loft angle of the golf club head 100. Theloft angle may vary based on the type of golf club (e.g., a long iron, amiddle iron, a short iron, a wedge, etc.). In one example, the loftangle may be between five degrees and seventy-five degrees. In anotherexample, the loft angle may be between twenty degrees and sixty degrees.The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

As illustrated in FIG. 14, the back portion 170 may include a back wallportion 1410 with one or more exterior weight ports along a periphery ofthe back portion 170, generally shown as a first set of exterior weightports 1420 (e.g., shown as weight ports 1421, 1422, 1423, and 1424) anda second set of exterior weight ports 1430 (e.g., shown as weight ports1431, 1432, 1433, 1434, 1435, 1436, and 1437). Each exterior weight portmay be associated with a port diameter. In one example, the portdiameter may be about 0.25 inch (6.35 millimeters). Any two adjacentexterior weight ports of the first set of exterior weight ports 1420 maybe separated by less than the port diameter. In a similar manner, anytwo adjacent exterior weight ports of the second set of exterior weightports 1430 may be separated by less than the port diameter. The firstand second exterior weight ports 1420 and 1430 may be exterior weightports configured to receive one or more weight portions. In particular,each weight portion of the first set 120 (e.g., shown as weight portions121, 122, 123, and 124) may be disposed in a weight port located at orproximate to the toe portion 140 and/or the top portion 180 on the backportion 170. For example, the weight portion 121 may be partially orentirely disposed in the weight port 1421. In another example, theweight portion 122 may be disposed in a weight port 1422 located in atransition region between the top portion 180 and the toe portion 140(e.g., a top-and-toe transition region). Each weight portion of thesecond set 130 (e.g., shown as weight portions 131, 132, 133, 134, 135,136, and 137) may be disposed in a weight port located at or proximateto the toe portion 140 and/or the sole portion 190 on the back portion170. For example, the weight portion 135 may be partially or entirelydisposed in the weight port 1435. In another example, the weight portion136 may be disposed in a weight port 1436 located in a transition regionbetween the sole portion 190 and the toe portion 140 (e.g., asole-and-toe transition region). As described in detail below, the firstand second sets of weight portions 120 and 130, respectively, may becoupled to the back portion 170 of the body portion 110 with variousmanufacturing methods and/or processes (e.g., a bonding process, awelding process, a brazing process, a mechanical locking method, anycombination thereof, or other suitable manufacturing methods and/orprocesses).

Alternatively, the golf club head 100 may not include (i) the first setof weight portions 120, (ii) the second set of weight portions 130, or(iii) both the first and second sets of weight portions 120 and 130. Inparticular, the back portion 170 of the body portion 110 may not includeweight ports at or proximate to the top portion 170 and/or the soleportion 190. For example, the mass of the first set of weight portions120 (e.g., 3 grams) and/or the mass of the second set of weight portions130 (e.g., 16.8 grams) may be integral part(s) the body portion 110instead of separate weight portion(s). The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

The first and second sets of weight portions 120 and 130, respectively,may have similar or different physical properties (e.g., color, shape,size, density, mass, volume, etc.). As a result, the first and secondsets of weight portions 120 and 130, respectively, may contribute to theornamental design of the golf club head 100. In the illustrated exampleas shown in FIG. 11, each of the weight portions of the first and secondsets 120 and 130, respectively, may have a cylindrical shape (e.g., acircular cross section). Alternatively, each of the weight portions ofthe first set 120 may have a first shape (e.g., a cylindrical shape)whereas each of the weight portions of the second set 130 may have asecond shape (e.g., a cubical shape). In another example, the first setof weight portions 120 may include two or more weight portions withdifferent shapes (e.g., the weight portion 121 may be a first shapewhereas the weight portion 122 may be a second shape different from thefirst shape). Likewise, the second set of weight portions 130 may alsoinclude two or more weight portions with different shapes (e.g., theweight portion 131 may be a first shape whereas the weight portion 132may be a second shape different from the first shape). Although theabove examples may describe weight portions having a particular shape,the apparatus, methods, and articles of manufacture described herein mayinclude weight portions of other suitable shapes (e.g., a portion of ora whole sphere, cube, cone, cylinder, pyramid, cuboidal, prism, frustum,or other suitable geometric shape). While the above examples and figuresmay depict multiple weight portions as a set of weight portions, eachset of the first and second sets of weight portions 120 and 130,respectively, may be a single piece of weight portion. In one example,the first set of weight portions 120 may be a single piece of weightportion instead of a series of four separate weight portions. In anotherexample, the second set of weight portions 130 may be a single piece ofweight portion instead of a series of seven separate weight portions.The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

Referring to FIGS. 12 and 13, for example, the first and second sets ofweight portions 120 and 130, respectively, may include threads,generally shown as 1210 and 1310, respectively, to engage withcorrespondingly configured threads in the weight ports to secure in theweight ports of the back portion 170 (generally shown as 1420 and 1430in FIG. 14). For example, each weight portion of the first and secondsets of weight portions 120 and 130, respectively, may be a screw. Thefirst and second sets of weight portions 120 and 130, respectively, maynot be readily removable from the body portion 110 with or without atool. Alternatively, the first and second sets of weight portions 120and 130, respectively, may be readily removable (e.g., with a tool) sothat a relatively heavier or lighter weight portion may replace one ormore of the weight portions of the first and second sets 120 and 130,respectively. In another example, the first and second sets of weightportions 120 and 130, respectively, may be secured in the weight portsof the back portion 170 with epoxy or adhesive so that the first andsecond sets of weight portions 120 and 130, respectively, may not bereadily removable. In yet another example, the first and second sets ofweight portions 120 and 130, respectively, may be secured in the weightports of the back portion 170 with both epoxy and threads so that thefirst and second sets of weight portions 120 and 130, respectively, maynot be readily removable. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

As mentioned above, the first and second sets of weight portions 120 and130, respectively, may be similar in some physical properties butdifferent in other physical properties. As illustrated in FIGS. 11-13,for example, each of the weight portions of the first and second sets120 and 130, respectively, may have a diameter 1110 of about 0.25 inch(6.35 millimeters) but the first and second sets of weight portions 120and 130, respectively, may be different in height. In particular, eachof the weight portions of the first set 120 may be associated with afirst height 1220 (FIG. 12), and each of the weight portion of thesecond set 130 may be associated with a second height 1320 (FIG. 13).The first height 1220 may be relatively shorter than the second height1320. In one example, the first height 1220 may be about 0.125 inch(3.175 millimeters) whereas the second height 1320 may be about 0.3 inch(7.62 millimeters). In another example, the first height 1220 may beabout 0.16 inch (4.064 millimeters) whereas the second height 1320 maybe about 0.4 inch (10.16 millimeters). Alternatively, the first height1220 may be equal to or greater than the second height 1320. Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

Referring back to FIG. 10, for example, the golf club head 100 may beassociated with a ground plane 1010, a horizontal midplane 1020, and atop plane 1030. In particular, the ground plane 1010 may be a tangentialplane to the sole portion 190 of the golf club head 100 when the golfclub head 100 is at an address position (e.g., the golf club head 100 isaligned to strike a golf ball). A top plane 1030 may be a tangentialplane to the top portion of the 180 of the golf club head 100 when thegolf club head 100 is at the address position. The ground and top planes1010 and 1030, respectively, may be substantially parallel to eachother. The horizontal midplane 1020 may be vertically halfway betweenthe ground and top planes 1010 and 1030, respectively.

To provide optimal perimeter weighting for the golf club head 100, thefirst set of weight portions 120 (e.g., weight portions 121, 122, 123,and 124) may be configured to counter-balance the weight of the hosel155. For example, as shown in FIG. 10, the first set of weight portions120 (e.g., weight portions 121, 122, 123 and 124) may be located nearthe periphery of the body portion 110 and extend from the top portion toa transition region 145 between the top portion 180 and the toe portion140, and from the transition region 145 to the toe portion 140. In otherwords, the first set of weight portions 120 may be located on the golfclub head 100 at a generally opposite location relative to the hosel155. According to one example, at least a portion of the first set ofweight portions 120 may be located near the periphery of the bodyportion 110 and extend through the transition region 145. According toanother example, at least a portion of the first set of weight portions120 may extend near the periphery of the body portion 110 and extendalong a portion of the top portion 180. According to another example, atleast a portion of the first set of weight portions 120 may extend nearthe periphery of the body portion 110 and extend along a portion of thetoe portion 140. The first set of weight portions 120 may be above thehorizontal midplane 1020 of the golf club head 100. At least a portionof the first set of weight portions 120 may be near the toe portion 140to increase the moment of inertia of the golf club head 100 about avertical axis of the golf club head 100 that extends through the centerof gravity of the golf club head 100. Accordingly, the first set ofweight portions 120 may be near the periphery of the body portion 110and extend through the top portion 180, the toe portion 140 and/or thetransition region 145 to counter-balance the weight of the hosel 155and/or increase the moment of inertia of the golf club head 100. Thelocations of the first set of weight portions 120 (i.e., the locationsof the first set of exterior weight ports 1420) and the physicalproperties and materials of construction of the weight portions of thefirst set of weight portions 120 may be determined to optimally affectthe weight, weight distribution, center of gravity, moment of inertiacharacteristics, structural integrity and/or or other static and/ordynamic characteristics of the golf club head 100. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

The second set of weight portions 130 (e.g., weight portions 131, 132,133, 134, 135, 136, and 137) may be configured to place the center ofgravity of the golf club head 100 at an optimal location and optimizethe moment of inertia of the golf club head about a vertical axis thatextends through the center of gravity of the golf club head 100.Referring to FIG. 10, all or a substantial portion of the second set ofweight portions 130 may be generally near the sole portion 190. Forexample, the second set of weight portions 130 (e.g., weight portions131, 132, 133, 134, 135, 136, and 137) may be near the periphery of thebody portion 110 and extend from the sole portion 190 to the toe portion140. As shown in the example of FIG. 10, the weight portions 131, 132,133, and 134 may be located near the periphery of the body portion 110and extend along the sole portion 190 to lower the center of gravity ofthe golf club head 100. The weight portions 135, 136 and 137 may belocated near the periphery of the body portion 110 and extend from thesole portion 190 to the toe portion 140 through a transition region 147between the sole portion 190 and the toe portion 140 to lower the centerof gravity and increase the moment of inertia of the golf club head 100about a vertical axis that extends through the center of gravity. Tolower the center of gravity of the golf club head 100, all or a portionof the second set of weight portions 130 may be located closer to thesole portion 190 than to the horizontal midplane 1020. For example, theweight portions 131, 132, 133, 134, 135, and 136 may be closer to thesole portion 190 than to the horizontal midplane 1020. The locations ofthe second set of weight portions 130 (i.e., the locations of the secondset of exterior weight ports 1430) and the physical properties andmaterials of construction of the weight portions of the second set ofweight portions 130 may be determined to optimally affect the weight,weight distribution, center of gravity, moment of inertiacharacteristics, structural integrity and/or or other static and/ordynamic characteristics of the golf club head 100. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

Turning to FIGS. 7-9, for example, the first and second sets of weightportions 120 and 130, respectively, may be located away from the backsurface 166 of the face portion 162 (e.g., not directly coupled to eachother). That is, the first and second sets of weight portions 120 and130, respectively, and the back surface 166 may be partially or entirelyseparated by an interior cavity 700 of the body portion 110. As shown inFIG. 14, for example, each exterior weight port of the first and secondsets of exterior weight ports 1420 and 1430 may include an opening(e.g., generally shown as 720 and 730) and a port wall (e.g., generallyshown as 725 and 735). The port walls 725 and 735 may be integralportions of the back wall portion 1410 (e.g., a section of the back wallportion 1410). Each of the openings 720 and 730 may be configured toreceive a weight portion such as weight portions 121 and 135,respectively. The opening 720 may be located at one end of the weightport 1421, and the port wall 725 may be located or proximate to at anopposite end of the weight port 1421. In a similar manner, the opening730 may be located at one end of the weight port 1435, and the port wall735 may be located at or proximate to an opposite end of the weight port1435. The port walls 725 and 735 may be separated from the face portion162 (e.g., separated by the interior cavity 700). The port wall 725 mayhave a distance 726 from the back surface 166 of the face portion 162 asshown in FIG. 9. The port wall 735 may have a distance 736 from the backsurface 166 of the face portion 162. The distances 726 and 736 may bedetermined to optimize the location of the center of gravity of the golfclub head 100 when the first and second sets of weight ports 1420 and1430, respectively, receive weight portions as described herein.According to one example, the distance 736 may be greater than thedistance 726 so that the center of gravity of the golf club head 100 ismoved toward the back portion 170. As a result, a width 740 of a portionof the interior cavity 700 below the horizontal midplane 1020 may begreater than a width 742 of the interior cavity 700 above the horizontalmidplane 1020. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

As discussed herein, the center of gravity (CG) of the golf club head100 may be relatively farther back away from the face portion 162 andrelatively lower towards a ground plane (e.g., one shown as 1010 in FIG.10) with all or a substantial portion of the second set of weightportions 130 being closer to the sole portion 190 than to the horizontalmidplane 1020 and the first and second sets of weight portions 120 and130, respectively being away from the back surface 166 than if thesecond set of weight portions 130 were directly coupled to the backsurface 166. The locations of the first and second sets of weight ports1420 and 1430 and the physical properties and materials of constructionof the weight portions of the first and second sets of weight portions120 and 130, respectively, may be determined to optimally affect theweight, weight distribution, center of gravity, moment of inertiacharacteristics, structural integrity and/or or other static and/ordynamic characteristics of the golf club head 100. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

While the figures may depict weight ports with a particularcross-section shape, the apparatus, methods, and articles of manufacturedescribed herein may include weight ports with other suitablecross-section shapes. In one example, the weight ports of the firstand/or second sets of weight ports 1420 and 1430 may have U-likecross-section shape. In another example, the weight ports of the firstand/or second set of weight ports 1420 and 1430 may have V-likecross-section shape. One or more of the weight ports associated with thefirst set of weight portions 120 may have a different cross-sectionshape than one or more weight ports associated with the second set ofweight portions 130. For example, the weight port 1421 may have a U-likecross-section shape whereas the weight port 1435 may have a V-likecross-section shape. Further, two or more weight ports associated withthe first set of weight portions 120 may have different cross-sectionshapes. In a similar manner, two or more weight ports associated withthe second set of weight portions 130 may have different cross-sectionshapes. The apparatus, methods, and articles of manufacture describedherein are not limited in this regard.

The first and second sets of weight portions 120 and 130, respectively,may be similar in mass (e.g., all of the weight portions of the firstand second sets 120 and 130, respectively, weigh about the same).Alternatively, the first and second sets of weight portions 120 and 130,respectively, may be different in mass individually or as an entire set.In particular, each of the weight portions of the first set 120 (e.g.,shown as 121, 122, 123, and 124) may have relatively less mass than anyof the weight portions of the second set 130 (e.g., shown as 131, 132,133, 134, 135, 136, and 137). For example, the second set of weightportions 130 may account for more than 50% of the total mass fromexterior weight portions of the golf club head 100. As a result, thegolf club head 100 may be configured to have at least 50% of the totalmass from exterior weight portions disposed below the horizontalmidplane 1020. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

In one example, the golf club head 100 may have a mass in the range ofabout 220 grams to about 330 grams based on the type of golf club (e.g.,a 4-iron versus a lob wedge). The body portion 110 may have a mass inthe range of about 200 grams to about 310 grams with the first andsecond sets of weight portions 120 and 130, respectively, having a massof about 20 grams (e.g., a total mass from exterior weight portions).Each of the weight portions of the first set 120 may have a mass ofabout one gram (1.0 g) whereas each of the weight portions of the secondset 130 may have a mass of about 2.4 grams. The sum of the mass of thefirst set of weight portions 120 may be about 3 grams whereas the sum ofthe mass of the first set of weight portions 130 may be about 16.8grams. The total mass of the second set of weight portions 130 may weighmore than five times as much as the total mass of the first set ofweight portions 120 (e.g., a total mass of the second set of weightportions 130 of about 16.8 grams versus a total mass of the first set ofweight portions 120 of about 3 grams). The golf club head 100 may have atotal mass of 19.8 grams from the first and second sets of weightportions 120 and 130, respectively (e.g., sum of 3 grams from the firstset of weight portions 120 and 16.8 grams from the second set of weightportions 130). Accordingly, the first set of weight portions 120 mayaccount for about 15% of the total mass from exterior weight portions ofthe golf club head 100 whereas the second set of weight portions 130 maybe account for about 85% of the total mass from exterior weight portionsof the golf club head 100. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

By coupling the first and second sets of weight portions 120 and 130,respectively, to the body portion 110 (e.g., securing the first andsecond sets of weight portions 120 and 130 in the weight ports on theback portion 170), the location of the center of gravity (CG) and themoment of inertia (MOI) of the golf club head 100 may be optimized. Inparticular, as described herein, the first and second sets of weightportions 120 and 130, respectively, may lower the location of the CGtowards the sole portion 190 and further back away from the face portion162. Further, the MOI may be higher as measured about a vertical axisextending through the CG (e.g., perpendicular to the ground plane 1010).The MOI may also be higher as measured about a horizontal axis extendingthrough the CG (e.g., extending towards the toe and heel portions 150and 160, respectively, of the golf club head 100). As a result, the clubhead 100 may provide a relatively higher launch angle and a relativelylower spin rate than a golf club head without the first and second setsof weight portions 120 and 130, respectively. The apparatus, methods,and articles of manufacture described herein are not limited in thisregard.

Alternatively, two or more weight portions in the same set may bedifferent in mass. In one example, the weight portion 121 of the firstset 120 may have a relatively lower mass than the weight portion 122 ofthe first set 120. In another example, the weight portion 131 of thesecond set 130 may have a relatively lower mass than the weight portion135 of the second set 130. With relatively greater mass at thetop-and-toe transition region and/or the sole-and-toe transition region,more weight may be distributed away from the center of gravity (CG) ofthe golf club head 100 to increase the moment of inertia (MOI) about thevertical axis through the CG.

Although the figures may depict the weight portions as separate andindividual parts, each set of the first and second sets of weightportions 120 and 130, respectively, may be a single piece of weightportion. In one example, all of the weight portions of the first set 120(e.g., shown as 121, 122, 123, and 124) may be combined into a singlepiece of weight portion (e.g., a first weight portion). In a similarmanner, all of the weight portions of the second set 130 (e.g., 131,132, 133, 134, 135, 136, and 137) may be combined into a single piece ofweight portion as well (e.g., a second weight portion). In this example,the golf club head 100 may have only two weight portions. While thefigures may depict a particular number of weight portions, theapparatus, methods, and articles of manufacture described herein mayinclude more or less number of weight portions. In one example, thefirst set of weight portions 120 may include two separate weightportions instead of three separate weight portions as shown in thefigures. In another example, the second set of weight portions 130 mayinclude five separate weight portions instead of seven separate weightportions a shown in the figures. Alternatively as mentioned above, theapparatus, methods, and articles of manufacture described herein may notinclude any separate weight portions (e.g., the body portion 110 may bemanufactured to include the mass of the separate weight portions asintegral part(s) of the body portion 110). The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

Referring back to FIGS. 7-9, for example, the body portion 110 may be ahollow body including the interior cavity 700 extending between thefront portion 160 and the back portion 170. Further, the interior cavity700 may extend between the top portion 180 and the sole portion 190. Theinterior cavity 700 may be associated with a cavity height 750 (H_(C)),and the body portion 110 may be associated with a body height 850(H_(B)). While the cavity height 750 and the body height 850 may varybetween the toe and heel portions 140 and 150, the cavity height 750 maybe at least 50% of a body height 850 (H_(C)>0.5*H_(B)). For example, thecavity height 750 may vary between 70-85% of the body height 850. Withthe cavity height 750 of the interior cavity 700 being greater than 50%of the body height 850, the golf club head 100 may produce relativelymore consistent feel, sound, and/or result when the golf club head 100strikes a golf ball via the face portion 162 than a golf club head witha cavity height of less than 50% of the body height. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

In one example, the interior cavity 700 may be unfilled (i.e., emptyspace). The body portion 100 with the interior cavity 700 may weightabout 100 grams less than the body portion 100 without the interiorcavity 700. Alternatively, the interior cavity 700 may be partially orentirely filled with an elastic polymer or elastomer material (e.g., aviscoelastic urethane polymer material such as Sorbothane® materialmanufactured by Sorbothane, Inc., Kent, Ohio), a thermoplastic elastomermaterial (TPE), a thermoplastic polyurethane material (TPU), and/orother suitable types of materials to absorb shock, isolate vibration,and/or dampen noise. For example, at least 50% of the interior cavity700 may be filled with a TPE material to absorb shock, isolatevibration, and/or dampen noise when the golf club head 100 strikes agolf ball via the face portion 162.

In another example, the interior cavity 700 may be partially or entirelyfilled with a polymer material such as an ethylene copolymer material toabsorb shock, isolate vibration, and/or dampen noise when the golf clubhead 100 strikes a golf ball via the face portion 162. In particular, atleast 50% of the interior cavity 700 may be filled with a high densityethylene copolymer ionomer, a fatty acid modified ethylene copolymerionomer, a highly amorphous ethylene copolymer ionomer, an ionomer ofethylene acid acrylate terpolymer, an ethylene copolymer comprising amagnesium ionomer, an injection moldable ethylene copolymer that may beused in conventional injection molding equipment to create variousshapes, an ethylene copolymer that can be used in conventional extrusionequipment to create various shapes, and/or an ethylene copolymer havinghigh compression and low resilience similar to thermoset polybutadienerubbers. For example, the ethylene copolymer may include any of theethylene copolymers associated with DuPont™ High-Performance Resin (HPF)family of materials (e.g., DuPont™ HPF AD1172, DuPont™ HPF AD1035,DuPont® HPF 1000 and DuPont™ HPF 2000), which are manufactured by E.I.du Pont de Nemours and Company of Wilmington, Del. The DuPont™ HPFfamily of ethylene copolymers are injection moldable and may be usedwith conventional injection molding equipment and molds, provide lowcompression, and provide high resilience. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

Turning to FIG. 15, for example, the face portion 162 may include afirst thickness 1510 (T₁), and a second thickness 1520 (T₂). The firstthickness 1510 may be a thickness of a section of the face portion 162adjacent to a groove 168 whereas the second thickness 1520 may be athickness of a section of the face portion 162 below the groove 168. Forexample, the first thickness 1510 may be a maximum distance between thefront surface 164 and the back surface 166. The second thickness 1520may be based on the groove 168. In particular, the groove 168 may have agroove depth 1525 (D_(groove)). The second thickness 1520 may be amaximum distance between the bottom of the groove 168 and the backsurface 166. The sum of the second thickness 1520 and the groove depth1525 may be substantially equal to the first thickness 1510 (e.g.,T₂+D_(groove)=T₁). Accordingly, the second thickness 1520 may be lessthan the first thickness 1510 (e.g., T₂<T₁).

To lower and/or move the CG of the golf club head 100 further back,weight from the front portion 160 of the golf club head 100 may beremoved by using a relatively thinner face portion 162. For example, thefirst thickness 1510 may be about 0.075 inch (1.905 millimeters) (e.g.,T₁=0.075 inch). With the support of the back wall portion 1410 to formthe interior cavity 700 and filling at least a portion of the interiorcavity 700 with an elastic polymer material, the face portion 162 may berelatively thinner (e.g., T₁<0.075 inch) without degrading thestructural integrity, sound, and/or feel of the golf club head 100. Inone example, the first thickness 1510 may be less than or equal to 0.060inch (1.524 millimeters) (e.g., T₁≦0.060 inch). In another example, thefirst thickness 1510 may be less than or equal to 0.040 inch (1.016millimeters) (e.g., T₁≦0.040 inch). Based on the type of material(s)used to form the face portion 162 and/or the body portion 110, the faceportion 162 may be even thinner with the first thickness 1510 being lessthan or equal to 0.030 inch (0.762 millimeters) (e.g., T₁≦0.030 inch).The groove depth 1525 may be greater than or equal to the secondthickness 1520 (e.g., D_(groove)≧T₂). In one example, the groove depth1525 may be about 0.020 inch (0.508 millimeters) (e.g., D_(groove)=0.020inch). Accordingly, the second thickness 1520 may be about 0.010 inch(0.254 millimeters) (e.g., T₂=0.010 inch). In another example, thegroove depth 1525 may be about 0.015 inch (0.381 millimeters), and thesecond thickness 1520 may be about 0.015 inch (e.g., D_(groove)=T₂=0.015inch). Alternatively, the groove depth 1525 may be less than the secondthickness 1520 (e.g., D_(groove)<T₂). Without the support of the backwall portion 1410 and the elastic polymer material to fill in theinterior cavity 700, a golf club head may not be able to withstandmultiple impacts by a golf ball on a face portion. In contrast to thegolf club head 100 as described herein, a golf club head with arelatively thin face portion but without the support of the back wallportion 1410 and the elastic polymer material to fill in the interiorcavity 700 (e.g., a cavity-back golf club head) may produce unpleasantsound (e.g., a tinny sound) and/or feel during impact with a golf ball.The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

Based on manufacturing processes and methods used to form the golf clubhead 100, the face portion 162 may include additional material at orproximate to a periphery of the face portion 162. Accordingly, the faceportion 162 may also include a third thickness 1530, and a chamferportion 1540. The third thickness 1530 may be greater than either thefirst thickness 1510 or the second thickness 1520 (e.g., T₃>T₁>T₂). Inparticular, the face portion 162 may be coupled to the body portion 110by a welding process. For example, the first thickness 1510 may be about0.030 inch (0.762 millimeters), the second thickness 1520 may be about0.015 inch (0.381 millimeters), and the third thickness 1530 may beabout 0.050 inch (1.27 millimeters). Accordingly, the chamfer portion1540 may accommodate some of the additional material when the faceportion 162 is welded to the body portion 110.

As illustrated in FIG. 16, for example, the face portion 162 may includea reinforcement section, generally shown as 1605, below one or moregrooves 168. In one example, the face portion 162 may include areinforcement section 1605 below each groove. Alternatively, faceportion 162 may include the reinforcement section 1605 below somegrooves (e.g., every other groove) or below only one groove. The faceportion 162 may include a first thickness 1610, a second thickness 1620,a third thickness 1630, and a chamfer portion 1640. The groove 168 mayhave a groove depth 1625. The reinforcement section 168 may define thesecond thickness 1620. The first and second thicknesses 1610 and 1620,respectively, may be substantially equal to each other (e.g., T₁=T₂). Inone example, the first and second thicknesses 1610 and 1620,respectively, may be about 0.030 inch (0.762 millimeters) (e.g.,T₁=T₂=0.030 inch). The groove depth 1625 may be about 0.015 inch (0.381millimeters), and the third thickness 1630 may be about 0.050 inch (1.27millimeters). The groove 168 may also have a groove width. The width ofthe reinforcement section 1605 may be greater than or equal to thegroove width. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

Alternatively, the face portion 162 may vary in thickness at and/orbetween the top portion 180 and the sole portion 190. In one example,the face portion 162 may be relatively thicker at or proximate to thetop portion 180 than at or proximate to the sole portion 190 (e.g.,thickness of the face portion 162 may taper from the top portion 180towards the sole portion 190). In another example, the face portion 162may be relatively thicker at or proximate to the sole portion 190 thanat or proximate to the top portion 180 (e.g., thickness of the faceportion 162 may taper from the sole portion 190 towards the top portion180). In yet another example, the face portion 162 may be relativelythicker between the top portion 180 and the sole portion 190 than at orproximate to the top portion 180 and the sole portion 190 (e.g.,thickness of the face portion 162 may have a bell-shaped contour). Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

Different from other golf club head designs, the interior cavity 700 ofthe body portion 110 and the location of the first and second sets ofweight portions 120 and 130, respectively, along the perimeter of thegolf club head 100 may result in a golf ball traveling away from theface portion 162 at a relatively higher ball launch angle and arelatively lower spin rate. As a result, the golf ball may travelfarther (i.e., greater total distance, which includes carry and rolldistances).

FIG. 17 depicts one manner in which the example golf club head describedherein may be manufactured. In the example of FIG. 17, the process 1700may begin with providing two or more weight portions, generally shown asthe first and second sets of weight portions 120 and 130, respectively(block 1710). The first and second sets of weight portions 120 and 130,respectively, may be made of a first material such as a tungsten-basedmaterial. In one example, the weight portions of the first and secondsets 120 and 130, respectively, may be tungsten-alloy screws.

The process 1700 may provide a body portion 110 having the face portion162, the interior cavity 700, and the back portion 170 with two or moreexterior weight ports, generally shown as 1420 and 1430 (block 1720).The body portion 110 may be made of a second material, which isdifferent than the first material. The body portion 110 may bemanufacture using an investment casting process, a billet forgingprocess, a stamping process, a computer numerically controlled (CNC)machining process, a die casting process, any combination thereof, orother suitable manufacturing processes. In one example, the body portion110 may be made of 17-4 PH stainless steel using a casting process. Inanother example, the body portion 110 may be made of other suitable typeof stainless steel (e.g., Nitronic® 50 stainless steel manufactured byAK Steel Corporation, West Chester, Ohio) using a forging process. Byusing Nitronic® 50 stainless steel to manufacture the body portion 110,the golf club head 100 may be relatively stronger and/or more resistantto corrosion than golf club heads made from other types of steel. Eachweight port of the body portion 110 may include an opening and a portwall. For example, the weight port 1421 may include the opening 720 andthe port wall 725 with the opening 720 and the port wall 725 being onopposite ends of each other. The interior cavity 700 may separate theport wall 725 of the weight port 1421 and the back surface 166 of theface portion 162. In a similar manner, the weight port 1835 may includethe opening 730 and the port wall 735 with the opening 730 and the portwall 735 being on opposite ends of each other. The interior cavity 700may separate the port wall 735 of the weight port 1435 and the backsurface 166 of the face portion 162.

The process 1700 may couple each of the first and second sets of weightportions 120 and 130 into one of the two or more exterior weight ports(blocks 1730). In one example, the process 1700 may insert and securethe weight portion 121 in the exterior weight port 1421, and the weightportion 135 in the exterior weight portion 1435. The process 1700 mayuse various manufacturing methods and/or processes to secure the firstand second sets of weight portions 120 and 130, respectively, in theexterior weight ports such as the weight ports 1421 and 1435 (e.g.,epoxy, welding, brazing, mechanical lock(s), any combination thereof,etc.).

The process 1700 may partially or entirely fill the interior cavity 700with an elastic polymer material (e.g., Sorbothane® material) or apolymer material (e.g., an ethylene copolymer material such as DuPont™HPF family of materials) (block 1740). In one example, at least 50% ofthe interior cavity 700 may be filled with the elastic polymer material.As mentioned above, the elastic polymer material may absorb shock,isolate vibration, and/or dampen noise in response to the golf club head100 striking a golf ball. In addition or alternatively, the interiorcavity 700 may be filled with a thermoplastic elastomer material and/ora thermoplastic polyurethane material. As illustrated in FIG. 18, forexample, the golf club head 100 may include one or more weight ports(e.g., one shown as 1431 in FIG. 14) with a first opening 1830 and asecond opening 1835. The second opening 1835 may be used to access theinterior cavity 700. In one example, the process 1700 (FIG. 17) may fillthe interior cavity 700 with an elastic polymer material by injectingthe elastic polymer material into the interior cavity 700 from the firstopening 1830 via the second opening 1835. The first and second openings1830 and 1835, respectively, may be same or different in size and/orshape. While the above example may describe and depict a particularweight port with a second opening, any other weight ports of the golfclub head 100 may include a second opening (e.g., the weight port 720).The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

Referring back to FIG. 17, the example process 1700 is merely providedand described in conjunction with other figures as an example of one wayto manufacture the golf club head 100. While a particular order ofactions is illustrated in FIG. 17, these actions may be performed inother temporal sequences. For example, two or more actions depicted inFIG. 17 may be performed sequentially, concurrently, or simultaneously.In one example, blocks 1710, 1720, 1730, and/or 1740 may be performedsimultaneously or concurrently. Although FIG. 17 depicts a particularnumber of blocks, the process may not perform one or more blocks. In oneexample, the interior cavity 700 may not be filled (i.e., block 1740 maynot be performed). The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

Referring back to FIGS. 1-14, the face portion 162 may include anon-smooth back surface to improve adhesion and/or mitigate delaminationbetween the face portion 162 and the elastic polymer material used tofill the interior cavity 700 (e.g., FIG. 7). Various methods and/orprocesses such as an abrasive blasting process (e.g., a bead blastingprocess, a sand blasting process, other suitable blasting process, orany combination thereof) and/or a milling (machining) process may beused to form the back surface 166 into a non-smooth surface. Forexample, the back surface 166 may have with a surface roughness (Ra)ranging from 0.5 to 250 μin (0.012 to 6.3 μm). The apparatus, methods,and articles of manufacture are not limited in this regard.

As illustrated in FIGS. 19-21, for example, a face portion 1900 mayinclude the front surface 1910, and the back surface 2010. The frontsurface 1910 may include one or more grooves, generally shown as 1920,extending longitudinally across the front surface 1910 (e.g., extendingbetween the toe portion 140 and the heel portion 150 of FIG. 1). Thefront surface 1910 may be used to impact a golf ball (not shown).

The back surface 2010 may also include one or more channels, generallyshown as 2020. The channels 2020 may extend longitudinally across theback surface 2010. The channels 2020 may be parallel or substantiallyparallel to each other. The channels 2020 may engage with the elasticpolymer material used to fill the interior cavity 700, and serve as amechanical locking mechanism between the face portion 1900 and theelastic polymer material. In particular, a channel 2100 may include anopening 2110, a bottom section 2120, and two sidewalls, generally shownas 2130 and 2132. The bottom section 2120 may be parallel orsubstantially parallel to the back surface 2010. The two sidewalls 2130and 2132 may be converging sidewalls (i.e., the two sidewalls 2130 and2132 may not be parallel to each other). The bottom section 2120 and thesidewalls 2130 and 2132 may form two undercut portions, generally shownas 2140 and 2142. That is, a width 2115 at the opening 2110 may be lessthan a width 2125 of the bottom section 2120. A cross section of thechannel 2100 may be symmetrical about an axis 2150. While FIG. 21 maydepict flat or substantially flat sidewalls, the two sidewalls 2130 and2132 may be curved (e.g., convex relative to each other).

Instead of flat or substantially flat sidewalls as shown in FIG. 21, achannel may include other types of sidewalls. As illustrated in FIG. 22,for example, a channel 2200 may include an opening 2210, a bottomsection 2220, and two sidewalls, generally shown as 2230 and 2232. Thebottom section 2220 may be parallel or substantially parallel to theback surface 2010. The two sidewalls 2230 and 2232 may be steppedsidewalls. The bottom section 2220 and the sidewalls 2230 and 2232 mayform two undercut portions, generally shown as 2240 and 2242. That is, awidth 2215 at the opening 2210 may be less than a width 2225 of thebottom section 2220. A cross section of the channel 2200 may besymmetrical about an axis 2250.

Instead of being symmetrical as shown in FIGS. 21 and 22, a channel maybe asymmetrical. As illustrated in FIG. 23, for another example, achannel 2300 may include an opening 2310, a bottom section 2320, and twosidewalls, generally shown as 2330 and 2332. The bottom section 2320 maybe parallel or substantially parallel to the back surface 2010. Thebottom section 2320 and the sidewall 2330 may form an undercut portion2340.

Referring to FIG. 24, for example, a channel 2400 may include an opening2410, a bottom section 2420, and two sidewalls, generally shown as 2430and 2432. The bottom section 2420 may not be parallel or substantiallyparallel to the back surface 2010. The two sidewalls 2430 and 2432 maybe parallel or substantially parallel to each other but one sidewall maybe longer than the other sidewall. The bottom section 2420 and thesidewall 2432 may form an undercut portion 2440.

In the example as shown in FIG. 25, a face portion 2500 may include aback surface 2510 with one or more channels, generally shown as 2520,extending laterally across the back surface 2510 (e.g., extendingbetween the top portion 180 and the sole portion 190 of FIG. 1). Inanother example as depicted in FIG. 26, a face portion 2600 may includea back surface 2610 with one or more channels, generally shown as 2620,extending diagonally across the back surface 2610. Alternatively, a faceportion may include a combination of channels extending in differentdirections across a back surface of the face portion (e.g., extendinglongitudinally, laterally, and/or diagonally). Turning to FIG. 27, foryet another example, a face portion 2700 may include a back surface 2710with one or more channels, generally shown as 2720, 2730, and 2740,extending in different directions across the back surface 2710. Inparticular, the face portion 2700 may include a plurality of channels2720 extending longitudinally across the back surface 2710, a pluralityof channels 2730 extending laterally across the back surface 2710, and aplurality of channels 2740 extending diagonally across the back surface2710.

Referring to FIG. 28, for example, the golf club head 100 may includethe face portion 162, a bonding portion 2810, and an elastic polymermaterial 2820. The bonding portion 2810 may provide connection,attachment and/or bonding of the elastic polymer material 2820 to theface portion 162. The bonding portion 2810 may be a bonding agent, acombination of bonding agents, a bonding structure or attachment device,a combination of bonding structures and/or attachment devices, and/or acombination of one or more bonding agents, one or more bondingstructures and/or one or more attachment devices. For example, the golfclub head 100 may include a bonding agent to improve adhesion and/ormitigate delamination between the face portion 162 and the elasticpolymer material used to fill the interior cavity 700 of the golf clubhead 100 (e.g., FIG. 7). In one example, the bonding portion 2810 may below-viscosity, organic, solvent-based solutions and/or dispersions ofpolymers and other reactive chemicals such as MEGUM™, ROBOND™, and/orTHIXON™ materials manufactured by the Dow Chemical Company, AuburnHills, Mich. In another example, the bonding portion 2810 may beLOCTITE® materials manufactured by Henkel Corporation, Rocky Hill, Conn.The bonding portion 2810 may be applied to the back surface 166 to bondthe elastic polymer material 2820 to the face portion 162 (e.g.,extending between the back surface 166 and the elastic polymer material2820). For example, the bonding portion 2810 may be applied when theinterior cavity 700 is filled with the elastic polymer material 2820 viaan injection-molding process. The apparatus, methods, and articles ofmanufacture are not limited in this regard.

FIG. 29 depicts one manner in which the interior cavity 700 of the golfclub head 100 or any of the golf club heads described herein ispartially or entirely filled with an elastic polymer material or anelastomer material. The process 2900 may begin with heating the golfclub head 100 to a certain temperature (block 2910). In one example, thegolf club head 100 may be heated to a temperature ranging between 150°C. to 250° C., which may depend on factors such as the vaporizationtemperature of the elastic polymer material to be injected in theinterior cavity 700. The elastic polymer material may then be heated toa certain temperature (block 2920). The elastic polymer material may bea non-foaming and injection-moldable thermoplastic elastomer (TPE)material. Accordingly, the elastic polymer material may be heated toreach a liquid or a flowing state prior to being injected into theinterior cavity 700. The temperature to which the elastic polymermaterial may be heated may depend on the type of elastic polymermaterial used to partially or fully fill the interior cavity 700. Theheated elastic polymer material may be injected into the interior cavity700 to partially or fully fill the interior cavity 700 (block 2930). Theelastic polymer material may be injected into the interior cavity 700from one or more of the weight ports described herein (e.g., one or moreweight ports of the first and second sets of weight ports 1420 and 1430,respectively, shown in FIG. 14). One or more other weight ports mayallow the air inside the interior cavity 700 displaced by the elasticpolymer material to vent from the interior cavity 700. In one example,the golf club head 100 may be oriented horizontally as shown in FIG. 14during the injection molding process. The elastic polymer material maybe injected into the interior cavity 700 from weight ports 1431 and1432. The weight ports 1421, 1422 and/or 1423 may serve as air ports forventing the displaced air from the interior cavity 700. Thus, regardlessof the orientation of the golf club head 100 during the injectionmolding process, the elastic polymer material may be injected into theinterior cavity 700 from one or more lower positioned weight ports whileone or more upper positioned weight ports may serve as air vents. Themold (i.e., the golf club head 100) may then be cooled passively (e.g.,at room temperature) or actively so that the elastic polymer materialreaches a solid state and adheres to the back surface 166 of the faceportion 162. The elastic polymer material may directly adhere to theback surface 166 of the face portion 162. Alternatively, the elasticpolymer material may adhere to the back surface 166 of the face portion162 with the aid of the one or more structures on the back surface 166and/or a bonding agent described herein (e.g., the bonding portion 2810shown in FIG. 28). The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

As discussed above, the elastic polymer material may be heated to aliquid state (i.e., non-foaming) and solidifies after being injectionmolded in the interior cavity 700. An elastic polymer material with alow modulus of elasticity may provide vibration and noise dampening forthe face portion 162 when the face portion 162 impacts a golf ball. Forexample, an elastic polymer material that foams when heated may providevibration and noise dampening. However, such a foaming elastic polymermaterial may not have sufficient rigidity to provide structural supportto a relatively thin face portion because of possible excessivedeflection and/or compression of the elastic polymer material whenabsorbing the impact of a golf ball. In one example, the elastic polymermaterial that is injection molded in the interior cavity 700 may have arelatively high modulus of elasticity to provide structural support tothe face portion 162 and yet elastically deflect to absorb the impactforces experienced by the face portion 162 when striking a golf ball.Thus, a non-foaming and injection moldable elastic polymer material witha relatively high modulus of elasticity may be used for partially orfully filling the interior cavity 700 to provide structural support andreinforcement for the face portion 162 in addition to providingvibration and noise dampening. That is, the non-foaming and injectionmoldable elastic polymer material may be a structural support portionfor the face portion 162. The apparatus, methods, and articles ofmanufacture are not limited in this regard.

FIG. 30 depicts one manner in which a bonding agent as described hereinmay be applied to a golf club head prior to partially of fully injectingan elastic polymer in the interior cavity 700. In the example of FIG.30, the process 3000 may begin with injecting a bonding agent on theback surface 166 of the face portion 162 (block 3010). The bonding agentmay be injected on the back surface 166 prior to or after heating thegolf club head as described above depending on the properties of thebonding agent. The bonding agent may be injected through one or more ofthe first set of weight ports 1420 and/or the second set of weight ports1430. The bonding agent may be injected on the back surface 166 throughseveral or all of the first set of weight ports 1420 and the second setof weight ports 1430. For example, an injection instrument such as anozzle or a needle may be inserted into each weight port until the tipor outlet of the instrument is near the back surface 166. The bondingagent may then be injected on the back surface 166 from the outlet ofthe instrument. Additionally, the instrument may be moved, rotatedand/or swiveled while inside the interior cavity 700 so that the bondingagent is injected onto an area of the back surface 166 surrounding theinstrument. For example, the outlet of the injection instrument may bemoved in a circular pattern while inside a weight port to inject thebonding agent in a corresponding circular pattern on the back surface166. Each of the first set of weight ports 1420 and the second set ofweight ports 1430 may be utilized to inject a bonding agent on the backsurface 166. However, utilizing all of first weight ports 1420 and/orthe second set of weight ports 1430 may not be necessary. For example,using every other adjacent weight port may be sufficient to inject abonding agent on the entire back surface 166. In another example, weightports 1421, 1422 1431, 1433 and 1436 may be used to inject the bondingagent on the back surface 166. The apparatus, methods, and articles ofmanufacture are not limited in this regard.

The process 3000 may also include spreading the bonding agent on theback surface 166 (block 3020) after injection of the bonding agent ontothe back surface 166 so that a generally uniform coating of the bondingagent is provided on the back surface 166. According to one example, thebonding agent may be spread on the back surface 166 by injecting airinto the interior cavity 700 through one or more of the first set ofweight ports 1420 and the second set of weight ports 1430. The air maybe injected into the interior cavity 700 and on the back surface 166 byinserting an air nozzle into one or more of the first set of weightports 1420 and the second set of weight ports 1430. According to oneexample, the air nozzle may be moved, rotated and/or swiveled at acertain distance from the back surface 166 so as to uniformly blow aironto the bonding agent to spread the bonding agent on the back surface166 for a uniform coating or a substantially uniform coating of thebonding agent on the back surface 166. The apparatus, methods, andarticles of manufacture are not limited in this regard.

The example process 3000 is merely provided and described in conjunctionwith other figures as an example of one way to manufacture the golf clubhead 100. While a particular order of actions is illustrated in FIG. 30,these actions may be performed in other temporal sequences. Further, twoor more actions depicted in FIG. 30 may be performed sequentially,concurrently, or simultaneously. The process 3000 may include a singleaction of injecting and uniformly or substantially uniformly coating theback surface 166 with the bonding agent. In one example, the bondingagent may be injected on the back surface 166 by being converted intofine particles or droplets (i.e., atomized) and sprayed on the backsurface 166. Accordingly, the back surface 166 may be uniformly orsubstantially uniformly coated with the bonding agent in one action. Asubstantially uniform coating of the back surface 166 with the bondingagent may be defined as a coating having slight non-uniformities due tothe injection process or the manufacturing process. However, such slightnon-uniformities may not affect the bonding of the elastic polymermaterial or the elastomer material to the back surface 166 with thebonding agent as described herein. For example, spraying the bondingagent on the back surface 166 may result in overlapping regions of thebonding agent having a slightly greater coating thickness than otherregions of the bonding agent on the back surface 166. The apparatus,methods, and articles of manufacture are not limited in this regard.

As described herein, any two or more of the weight portions may beconfigured as a single weight portion. In the example of FIGS. 31 and32, a golf club head 3100 may include a body portion 3110 and two ormore weight portions, generally shown as a first set of weight portions3120 (e.g., shown as weight portions 3121, 3122, 3123, and 3124) and asecond weight portion 3130. The body portion 3110 may include a toeportion 3140, a heel portion 3150, a front portion (not shown), a backportion 3170, a top portion 3180, and a sole portion 3190. The frontportion may be similar in many respects to the front portion 160 of thegolf club head 100. Accordingly, details of the front portion of thegolf club head 3100 are not provided.

The body portion 3110 may be made of a first material whereas the firstset of weight portions 3120 and the second weight portion 3130 may bemade of a second material. The first and second materials may be similaror different materials. For example, the body portion 3110 may bepartially or entirely made of a steel-based material (e.g., 17-4 PHstainless steel, Nitronic® 50 stainless steel, maraging steel or othertypes of stainless steel), a titanium-based material, an aluminum-basedmaterial (e.g., a high-strength aluminum alloy or a composite aluminumalloy coated with a high-strength alloy), any combination thereof,and/or other suitable types of materials. The first set of weightportions 3120 and the second weight portion 3130 may be partially orentirely made of a high-density material such as a tungsten-basedmaterial or other suitable types of materials. Alternatively, the bodyportion 3110 and/or the first set of weight portions 3120 and the secondweight portion 3130 may be partially or entirely made of a non-metalmaterial (e.g., composite, plastic, etc.). The apparatus, methods, andarticles of manufacture are not limited in this regard.

The golf club head 3100 may be an iron-type golf club head (e.g., a1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron, a 7-iron, an8-iron, a 9-iron, etc.) or a wedge-type golf club head (e.g., a pitchingwedge, a lob wedge, a sand wedge, an n-degree wedge such as 44 degrees(°), 48°, 52°, 56°, 60°, etc.). Although FIGS. 31 and 32 may depict aparticular type of club head, the apparatus, methods, and articles ofmanufacture described herein may be applicable to other types of clubheads (e.g., a driver-type club head, a fairway wood-type club head, ahybrid-type club head, a putter-type club head, etc.). The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

The toe portion 3140 and the heel portion 3150 may be on opposite endsof the body portion 3110. The heel portion 3150 may include a hoselportion 3155 configured to receive a shaft (not shown) with a grip (notshown) on one end and the golf club head 3100 on the opposite end of theshaft to form a golf club.

The back portion 3170 may include a back wall portion 3210 with one ormore exterior weight ports along a periphery of the back portion 3170,generally shown as a first set of exterior weight ports 3220 (e.g.,shown as weight ports 3221, 3222, 3223, and 3224) and a second weightport 3230. Each exterior weight port of the first set of weight ports3220 may be associated with a port diameter. In one example, the portdiameter may be about 0.25 inch (6.35 millimeters). Any two adjacentexterior weight ports of the first set of exterior weight ports 3220 maybe separated by less than the port diameter. The first set of weightports 3220 and the second weight port 3230 may be exterior weight portsconfigured to receive one or more weight portions.

Each weight portion of the first set of weight portions 3120 (e.g.,shown as weight portions 3121, 3122, 3123, and 3124) may be disposed ina weight port of the first set of weight ports 3220 (e.g., shown asweight ports 3221, 3222, 3223, and 3224) located at or proximate to thetoe portion 3140 and/or the top portion 3180 on the back portion 3170.For example, the weight portion 3121 may be partially or entirelydisposed in the weight port 3221. In another example, the weight portion3122 may be disposed in a weight port 3222 located in a transitionregion between the top portion 3180 and the toe portion 3140 (e.g., atop-and-toe transition region). The configuration of the first set ofweight ports 3220 and the first set of weight portions 3120 is similarto many respects to the golf club head 100. Accordingly, a detaileddescription of the configuration of the first set of weight ports 3220and the first set of weight portions 3120 is not provided.

The second weight port 3230 may be a recess extending from the toeportion 3140 or a location proximate to the toe portion 3140 to the soleportion or a location proximate to the sole portion 3190 and through thetransition region between the toe portion 3140 and the sole portion3190. Accordingly, as shown in FIG. 31, the second weight port 3230 mayresemble an L-shaped recess. The second weight portion 3130 may resemblethe shape of the second weight port 3230 and may be configured to bedisposed in the second weight port 3230. The second weight portion 3130may be partially or fully disposed in the weight port 3230. The secondweight portion 3130 may have any shape such as oval, rectangular,triangular, or any geometric or non-geometric shape. The second weightport 3230 may be shaped similar to the second weight portion 3130.However, portions of the second weight portion 3130 that are inserted inthe second weight port 3230 may have similar shapes as the weight port3230. As described in detail herein, any of the weight portionsdescribed herein, including the weight portions 3120 and the secondweight portion 3130 may be coupled to the back portion 3170 of the bodyportion 3110 with various manufacturing methods and/or processes (e.g.,a bonding process, a welding process, a brazing process, a mechanicallocking method, any combination thereof, or other suitable manufacturingmethods and/or processes).

The second weight portion 3130 may be configured to place the center ofgravity of the golf club head 100 at an optimal location and optimizethe moment of inertia of the golf club head about a vertical axis thatextends through the center of gravity of the golf club head 3100. All ora substantial portion of the second weight portion 3130 may be generallynear the sole portion 3190. For example, the second weight portion 3130may be near the periphery of the body portion 3110 and extend from thesole portion 3190 to the toe portion 3190. As shown in the example ofFIG. 32, the second weight portion 3130 may be located near theperiphery of the body portion 3110 and partially or substantially extendalong the sole portion 3190 to lower the center of gravity of the golfclub head 3100. A portion of the second weight portion 3130 may belocated near the periphery of the body portion 3110 and extend from thesole portion 3190 to the toe portion 3140 through a transition region3147 between the sole portion 3190 and the toe portion 3140 to lower thecenter of gravity and increase the moment of inertia of the golf clubhead 3100 about a vertical axis that extends through the center ofgravity. To lower the center of gravity of the golf club head 3100, allor a portion of the second weight portion 3130 may be located closer tothe sole portion 3190 than to a horizontal midplane 3260 of the golfclub head 3100. The location of the second weight portion 3130 (i.e.,the location of the weight port 3230) and the physical properties andmaterials of construction of the weight portions of the second weightport 3130 may be determined to optimally affect the weight, weightdistribution, center of gravity, moment of inertia characteristics,structural integrity and/or or other static and/or dynamiccharacteristics of the golf club head 3100. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

The weight portions of the first set of weight portions 3120 may havesimilar or different physical properties (e.g., color, shape, size,density, mass, volume, etc.). In the illustrated example as shown inFIG. 32, each of the weight portions of the first set of weight portions3120 may have a cylindrical shape (e.g., a circular cross section).Alternatively, each of the weight portions of the first set of weightportions 3120 may have different shapes. Although the above examples maydescribe weight portions having a particular shape, the apparatus,methods, and articles of manufacture described herein may include weightportions of other suitable shapes (e.g., a portion of or a whole sphere,cube, cone, cylinder, pyramid, cuboidal, prism, frustum, or othersuitable geometric shape). The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

In the example of FIGS. 33-42, a golf club head 3300 may include a bodyportion 3310, and two or more weight portions, generally shown as afirst set of weight portions 3320 (e.g., shown as weight portions 3321and 3322) and a second set of weight portions 3330 (e.g., shown asweight portions 3331, 3332, 3333, 3334 and 3335). The body portion 3310may include a toe portion 3340, a heel portion 3350, a front portion3360, a back portion 3370, a top portion 3380, and a sole portion 3390.The heel portion 3350 may include a hosel portion 3355 configured toreceive a shaft (not shown) with a grip (not shown) on one end and thegolf club head 3300 on the opposite end of the shaft to form a golfclub.

The body portion 3310 may be made of a first material whereas the firstand second sets of weight portions 3320 and 3330, respectively, may bemade of a second material. The first and second materials may be similaror different materials. The materials from which the golf club head3300, weight portions 3320 and/or weight portions 3330 are constructedmay be similar in many respects to any of the golf club heads and theweight portions described herein such as the golf club head 100.Accordingly, a detailed description of the materials of construction ofthe golf club head 3300, weight portions 3320 and/or weight 3330 are notdescribed in detail. The apparatus, methods, and articles of manufactureare not limited in this regard.

The golf club head 3300 may be an iron-type golf club head (e.g., a1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron, a 7-iron, an8-iron, a 9-iron, etc.) or a wedge-type golf club head (e.g., a pitchingwedge, a lob wedge, a sand wedge, an n-degree wedge such as 44 degrees(°), 48°, 52°, 56°, 60°, etc.). Although FIGS. 33-42 may depict aparticular type of club head, the apparatus, methods, and articles ofmanufacture described herein may be applicable to other types of clubheads (e.g., a driver-type club head, a fairway wood-type club head, ahybrid-type club head, a putter-type club head, etc.). The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

The front portion 3360 may include a face portion 3362 (e.g., a strikeface). The face portion 3362 may include a front surface 3364 and a backsurface 3366 (shown in FIG. 37). The front surface 3364 may include oneor more grooves 3368 extending between the toe portion 3340 and the heelportion 3350. While the figures may depict a particular number ofgrooves, the apparatus, methods, and articles of manufacture describedherein may include more or less grooves. The face portion 3362 may beused to impact a golf ball (not shown). The face portion 3362 may be anintegral portion of the body portion 3310. Alternatively, the faceportion 3362 may be a separate piece or an insert coupled to the bodyportion 3310 via various manufacturing methods and/or processes (e.g., abonding process such as adhesive, a welding process such as laserwelding, a brazing process, a soldering process, a fusing process, amechanical locking or connecting method, any combination thereof, orother suitable types of manufacturing methods and/or processes). Theface portion 3362 may be associated with a loft plane that defines theloft angle of the golf club head 3300. The loft angle may vary based onthe type of golf club (e.g., a long iron, a middle iron, a short iron, awedge, etc.). In one example, the loft angle may be between five degreesand seventy-five degrees. In another example, the loft angle may bebetween twenty degrees and sixty degrees. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

As illustrated in FIG. 36, the back portion 3370 may include a back wallportion 3510 with one or more exterior weight ports along a periphery ofthe back portion 3370, generally shown as a first set of exterior weightports 3520 (e.g., shown as weight ports 3521 and 3522) and a second setof exterior weight ports 3530 (e.g., shown as weight ports 3531, 3532,3533, 3534 and 3535). Each exterior weight port may be defined by anopening in the back wall portion 3510. Each exterior weight port may beassociated with a port diameter. In one example, the port diameter maybe about 0.25 inch (6.35 millimeters). The weight ports of the first setof exterior weight ports 3520 may be separated by less than the portdiameter or the port diameter of any of the two adjacent weight ports ofthe first set of exterior weight ports 3520. In a similar manner, anytwo adjacent exterior weight ports of the second set of exterior weightports 3530 may be separated by less than the port diameter or the portdiameter of any of the two adjacent weight ports of the second set ofexterior weight ports 3530. The first and second exterior weight ports3520 and 3530, respectively, may be exterior weight ports configured toreceive one or more weight portions. In particular, each weight portionof the first set of weight portions 3320 (e.g., shown as weight portions3321 and 3322) may be disposed in a weight port located at or proximateto the toe portion 3340 and/or the top portion 3380 on the back portion3370. For example, the weight portion 3321 may be partially or entirelydisposed in the weight port 3521. In another example, the weight portion3322 may be disposed in the weight port 3522 located in a transitionregion between the top portion 3380 and the toe portion 3340 (e.g., atop-and-toe transition region). Each weight portion of the second set ofweight portions 3330 (e.g., shown as weight portions 3331, 3332, 3333,3334 and 3335) may be disposed in a weight port located at or proximateto the toe portion 3340 and/or the sole portion 3390 on the back portion3370. For example, the weight portion 3333 may be partially or entirelydisposed in the weight port 3533. In another example, the weight portion3335 may be disposed in a weight port 3535 located in a transitionregion between the sole portion 3390 and the toe portion 3340 (e.g., asole-and-toe transition region). In another example, any of the weightportions of the first set of weight portions 3320 and the second set ofweight portions 3330 may disposed in any of the weight ports of thefirst set of weight ports 3520 and the second set of weight ports 3530.As described in detail herein, the first and second sets of weightportions 3320 and 3330, respectively, may be coupled to the back portion3370 of the body portion 3310 with various manufacturing methods and/orprocesses (e.g., a bonding process, a welding process, a brazingprocess, a mechanical locking method, any combination thereof, or othersuitable manufacturing methods and/or processes).

Alternatively, the golf club head 3300 may not include (i) the first setof weight portions 3320, (ii) the second set of weight portions 3330, or(iii) both the first and second sets of weight portions 3320 and 3330.In particular, the back portion 3370 of the body portion 3310 may notinclude weight ports at or proximate to the top portion 3370 and/or thesole portion 3390. For example, the mass of the first set of weightportions 3320 (e.g., 3 grams) and/or the mass of the second set ofweight portions 3330 (e.g., 16.8 grams) may be integral part(s) the bodyportion 3310 instead of separate weight portion(s). The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

The first and second sets of weight portions 3320 and 3330,respectively, may have similar or different physical properties (e.g.,color, shape, size, density, mass, volume, etc.). As a result, the firstand second sets of weight portions 3320 and 3330, respectively, maycontribute to the ornamental design of the golf club head 3300. Thephysical properties of the first and second sets of weight portions 3320and 3330 may be similar in many respect to any of the weight portionsdescribed herein, such as the weight portions shown in the example ofFIG. 11. Furthermore, the devices and/or methods by which the first andsecond set of weight portions 3320 and 3330 are coupled to the golf clubhead 3300 may be similar in many respect to any of the weight portionsdescribed herein, such as the weight portions shown in the example ofFIGS. 12 and 13. Accordingly, a detailed description of the physicalproperties of the first and second sets of weight portions 3320 and3330, and the devices and/or methods by which the first and second setsof weight portions 3320 and 3330 are coupled to the golf club head 3300are not described in detail herein. The apparatus, methods, and articlesof manufacture described herein are not limited in this regard.

As illustrated in FIG. 34, golf club head 3300 may be associated with aground plane 4110, a horizontal midplane 4120, and a top plane 4130. Inparticular, the ground plane 4110 may be a plane that may besubstantially parallel with the ground and be tangential to the soleportion 3390 of the golf club head 3300 when the golf club head 3300 isat an address position (e.g., the golf club head 3300 is aligned tostrike a golf ball). A top plane 4130 may be a tangential plane to thetop portion of the 3380 of the golf club head 3300 when the golf clubhead 3300 is at the address position. The ground and top planes 4110 and4130, respectively, may be substantially parallel to each other. Thehorizontal midplane 4120 may be located at half the vertical distancebetween the ground and top planes 4110 and 4130, respectively.

To provide optimal perimeter weighting for the golf club head 3300, thefirst set of weight portions 3320 (e.g., weight portions 3321 and 3322)may be configured to counter-balance the weight of the hosel 3355 and/orincrease the moment of inertia of the golf club head 3300 about avertical axis of the golf club head 3300 that extends through the centerof gravity of the golf club head 3300. For example, as shown in FIG. 34,the first set of weight portions 3320 (e.g., weight portions 3321 and3322) may be located near the periphery of the body portion 3310 andextend in a transition region 3345 between the top portion 3380 and thetoe portion 3340. In another example, the first set of weight portions3320 (e.g., weight portions 3321 and 3322) may be located near theperiphery of the body portion 3310 and extend proximate to the toeportion 3340. The locations of the first set of weight portions 3320(i.e., the locations of the first set of weight ports 3520) and thephysical properties and materials of construction of the weight portionsof the first set of weight portions 3320 may be determined to optimallyaffect the weight, weight distribution, center of gravity, moment ofinertia characteristics, structural integrity and/or or other staticand/or dynamic characteristics of the golf club head 3300. Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

The second set of weight portions 3330 (e.g., weight portions 3331,3332, 3333, 3334 and 3335) may be configured to place the center ofgravity of the golf club head 3300 at an optimal location and/oroptimize the moment of inertia of the golf club head about a verticalaxis that extends through the center of gravity of the golf club head3300. Referring to FIG. 34, all or a substantial portion of the secondset of weight portions 3330 may be near the sole portion 3390. Forexample, the second set of weight portions 3330 (e.g., weight portions3331, 3332, 3333, 3334 and 3335) may extend at or near the sole portion3390 between the toe portion 3340 and the heel portion 3350 to lower thecenter of gravity of the golf club head 100. The weight portions 3334and 3335 may be located closer to the toe portion 3340 than to the heelportion 3350 and/or at or near a transition region 3347 between the soleportion 3390 and the toe portion 3340 to increase the moment of inertiaof the golf club head 3300 about a vertical axis that extends throughthe center of gravity. Some of the weight portions of the second set ofweight portions 3330 may be located at the toe portion. To lower thecenter of gravity of the golf club head 3300, all or a portion of thesecond set of weight portions 3330 may be located closer to the soleportion 3390 than to the horizontal midplane 4120. The locations of thesecond set of weight portions 3330 (i.e., the locations of the secondset of weight ports 3530) and the physical properties and materials ofconstruction of the weight portions of the second set of weight portions3330 may be determined to optimally affect the weight, weightdistribution, center of gravity, moment of inertia characteristics,structural integrity and/or or other static and/or dynamiccharacteristics of the golf club head 3300. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

Turning to FIG. 37, for example, the first and second sets of weightportions 3320 and 3330, respectively, may be located away from the backsurface 3366 of the face portion 3362 (e.g., not directly coupled toeach other). That is, the first and second sets of weight portions 3320and 3330, respectively, and the back surface 3366 may be partially orentirely separated by an interior cavity 3800 of the body portion 3300.For example, each exterior weight port of the first and second sets ofexterior weight ports 3320 and 3330 may include an opening (e.g.,generally shown as 3820 and 3830) and a port wall (e.g., generally shownas 3825 and 3835). The port walls 3825 and 3835 may be integral portionsof the back wall portion 3510 (e.g., a section of the back wall portion3510). Each of the openings 3820 and 3830 may be configured to receive aweight portion such as weight portions 3321 and 3335, respectively. Theopening 3820 may be located at one end of the weight port 3521, and theport wall 3825 may be located or proximate to at an opposite end of theweight port 3521. In a similar manner, the opening 3830 may be locatedat one end of the weight port 3535, and the port wall 3835 may belocated at or proximate to an opposite end of the weight port 3535. Theport walls 3825 and 3835 may be separated from the face portion 3362(e.g., separated by the interior cavity 3800). Each port wall of thefirst set of weight ports 3520, such as the port wall 3825 may have adistance 3826 from the back surface 3366 of the face portion 3362 asshown in FIG. 37. Each port wall of the second set of weight ports 3530,such as the port wall 3835 may have a distance 3836 from the backsurface 3366 of the face portion 3362. The distances 3826 and 3836 maybe determined to optimize the location of the center of gravity of thegolf club head 3300 when the first and second sets of weight ports 3520and 3530, respectively, receive weight portions as described herein.According to one example, the distance 3836 may be greater than thedistance 3826 so that the center of gravity of the golf club head 3300is moved toward the back portion 3370 and/or lowered toward the soleportion 3390. According to one example, the distance 3836 may be greaterthan the distance 3826 by a factor ranging from about 1.5 to about 4. Inother words, the distance 3836 may be about 1.5 times to about 4 timesgreater than the distance 3826. As a result, a width 3840 (shown in FIG.38) of a portion of the interior cavity 3800 below the horizontalmidplane 4120 may be greater than a width 3842 of the interior cavity3800 above the horizontal midplane 4120. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

As discussed herein, the center of gravity (CG) of the golf club head3300 may be relatively farther back from the face portion 3362 andrelatively lower towards a ground plane (e.g., one shown as 4110 in FIG.34) as compared to a golf club without a width 3840 of a portion of theinterior cavity 3800 being greater than a width 3842 of the interiorcavity 3800 as described herein, with all or a substantial portion ofthe second set of weight portions 3330 being closer to the sole portion3390 than to the horizontal midplane 4120, and the first and second setsof weight portions 3320 and 3330, respectively, being away from the backsurface 3366 than if the second set of weight portions 3330 weredirectly coupled to the back surface 3366. The locations of the firstand second sets of weight ports 3520 and 3530 and the physicalproperties and materials of construction of the weight portions of thefirst and second sets of weight portions 3320 and 3330, respectively,may be determined to optimally affect the weight, weight distribution,center of gravity, moment of inertia characteristics, structuralintegrity and/or or other static and/or dynamic characteristics of thegolf club head 3300. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

While the figures may depict weight ports with a particularcross-section shape, the apparatus, methods, and articles of manufacturedescribed herein may include weight ports with other suitablecross-section shapes. The weight ports of the first and/or second setsof weight ports 3520 and 3530 may have cross-sectional shapes that aresimilar to the cross-sectional shapes of any of the weight portsdescribed herein. Accordingly, the detailed description of thecross-sectional shapes of the weight ports 3520 and 3530 are notdescribed in detail. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

The first and second sets of weight portions 3320 and 3330,respectively, may be similar in mass (e.g., all of the weight portionsof the first and second sets 3320 and 3330, respectively, weigh aboutthe same). Alternatively, the first and second sets of weight portions3320 and 3330, respectively, may be different in mass individually or asan entire set. In particular, each of the weight portions of the firstset 3320 (e.g., shown as 3321 and 3322) may have relatively less massthan any of the weight portions of the second set 3330 (e.g., shown as3331, 3332, 3333, 3334 and 3335). For example, the second set of weightportions 3330 may account for more than 50% of the total mass fromexterior weight portions of the golf club head 3300. As a result, thegolf club head 3300 may be configured to have at least 50% of the totalmass from exterior weight portions disposed below the horizontalmidplane 4120. In one example, the total mass from exterior weightportions may be greater below the horizontal midplane 4120 that thetotal mass from exterior weight portions above the horizontal midplane4120. The apparatus, methods, and articles of manufacture describedherein are not limited in this regard.

In one example, the golf club head 3300 may have a mass in the range ofabout 220 grams to about 330 grams based on the type of golf club (e.g.,a 4-iron versus a lob wedge). The body portion 3310 may have a mass inthe range of about 200 grams to about 310 grams with the first andsecond sets of weight portions 3320 and 3330, respectively, having amass of about 20 grams (e.g., a total mass from exterior weightportions). Each of the weight portions of the first set 3320 may have amass of about one gram (1.0 g) whereas each of the weight portions ofthe second set 3330 may have a mass of about 2.4 grams. The sum of themass of the first set of weight portions 3320 may be about 3 gramswhereas the sum of the mass of the first set of weight portions 3330 maybe about 16.8 grams. The total mass of the second set of weight portions3330 may weigh more than five times as much as the total mass of thefirst set of weight portions 3320 (e.g., a total mass of the second setof weight portions 3330 of about 16.8 grams versus a total mass of thefirst set of weight portions 3320 of about 3 grams). The golf club head3300 may have a total mass of 19.8 grams from the first and second setsof weight portions 3320 and 3330, respectively (e.g., sum of 3 gramsfrom the first set of weight portions 3320 and 16.8 grams from thesecond set of weight portions 3330). Accordingly, the first set ofweight portions 3320 may account for about 15% of the total mass fromexterior weight portions of the golf club head 3300 whereas the secondset of weight portions 3330 may be account for about 85% of the totalmass from exterior weight portions of the golf club head 3300. Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

By coupling the first and second sets of weight portions 3320 and 3330,respectively, to the body portion 3310 (e.g., securing the first andsecond sets of weight portions 3320 and 3330 in the weight ports on theback portion 3370), the location of the center of gravity (CG) and themoment of inertia (MOI) of the golf club head 3300 may be optimized. Inparticular, the first and second sets of weight portions 3320 and 3330,respectively, may lower the location of the CG towards the sole portion3390 and further back away from the face portion 3362. Further, the MOImay be higher as measured about a vertical axis extending through the CG(e.g., perpendicular to the ground plane 4110). The MOI may also behigher as measured about a horizontal axis extending through the CG(e.g., extending towards the toe and heel portions 3350 and 3360,respectively, of the golf club head 3300). As a result, the club head3300 may provide a relatively higher launch angle and a relatively lowerspin rate than a golf club head without the first and second sets ofweight portions 3320 and 3330, respectively. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

Alternatively, two or more weight portions in the same set may bedifferent in mass. In one example, the weight portion 3321 of the firstset 3320 may have a relatively lower mass than the weight portion 3322of the first set 3320. In another example, the weight portion 3331 ofthe second set 3330 may have a relatively lower mass than the weightportion 3335 of the second set 3330. With relatively greater mass at thetop-and-toe transition region and/or the sole-and-toe transition region,more weight may be distributed away from the center of gravity (CG) ofthe golf club head 3300 to increase the moment of inertia (MOI) aboutthe vertical axis through the CG.

Although the figures may depict the weight portions as separate andindividual parts, each set of the first and second sets of weightportions 3320 and 3330, respectively, may be a single piece of weightportion. In one example, all of the weight portions of the first set3320 (e.g., shown as 3321 and 3322) may be combined into a single pieceof weight portion (e.g., a first weight portion). In a similar manner,all of the weight portions of the second set 3330 (e.g., 3331, 3332,3333, 3334 and 3335) may be combined into a single piece of weightportion as well (e.g., a second weight portion) similar to the exampleof FIG. 32. While the figures may depict a particular number of weightportions, the apparatus, methods, and articles of manufacture describedherein may include more or less number of weight portions. Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

The body portion 3310 may be a hollow body including the interior cavity3800 extending between the front portion 3360 and the back portion 3370.Further, the interior cavity 3800 may extend between the top portion3380 and the sole portion 3390. The interior cavity 3800 may beassociated with a cavity height 3850 (H_(C)), and the body portion 3310may be associated with a body height 3950 (H_(B)). While the cavityheight 3850 and the body height 3950 may vary between the toe and heelportions 3340 and 3350, and the top and sole portions 3370 and 3390, thecavity height 3850 may be at least 50% of a body height 3950(H_(C)>0.5*H_(B)). For example, the cavity height 3850 may vary between70%-85% of the body height 3950. With the cavity height 3850 of theinterior cavity 3800 being greater than 50% of the body height 3950, thegolf club head 3300 may produce relatively more consistent feel, sound,and/or result when the golf club head 3300 strikes a golf ball via theface portion 3362 than a golf club head with a cavity height of lessthan 50% of the body height. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

The interior cavity 3800 may be associated with a cavity width 3840(W_(C)), and the body portion 3310 may be associated with a body width3990 (W_(B)). The cavity width 3840 and the body width 3990 may varybetween the top portion 3380 and the sole portion 3390 and between thetoe portion 3340 and the heel portion 3350. The cavity width 3840 may beat least 50% of a body width 3990 (W_(C)>0.5*W_(B)) at certain regionson the body portion 3310 between the top and sole portions 3370 and 3390and between the toe and heel portions 3340 and 3350. According toanother example, the cavity width 3840 may vary between about 40%-60% ofa body width 3990 at certain regions between the top and sole portions3380 and 3390. According to another example, the cavity width 3840 mayvary between about 30%-70% of a body width 3990 at certain regionsbetween the top and sole portions 3380 and 3390. According to anotherexample, the cavity width 3840 may vary between about 20%-80% of a bodywidth 3990 at certain regions between the top and sole portions 3380.For example, the cavity width 3840 may vary between about 20%-80% of thebody width 3990 at or below the horizontal midplane 4120. With thecavity width 3890 of the interior cavity 3800 that may vary betweenabout 20% or more to about 80% or less of the body width 3990 at orbelow the horizontal midplane 4120, a substantial portion of the mass ofthe golf club head 3300 may be moved lower and farther back as comparedto a golf club head with a cavity width of less than about 20% of thebody width. Further, the golf club head 3300 may produce relatively moreconsistent feel, sound, and/or result when the golf club head 3300strikes a golf ball via the face portion 3362 than a golf club head witha cavity width of less than about 20% of the body width. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

To provide an inner cavity 3800 having cavity a width 3840 that may varybetween about 20-80% of a body width 3990 at or below the horizontalmidplane 4120, to lower the CG of the golf club head 3300, and/or tomove the CG of the golf club head 3300 farther back relative to the faceportion 3360, the back portion 3370 may have a recessed portion 3410(shown in FIGS. 35, 36 and 39) that may extend between a location nearthe horizontal midplane 4120 and a location at or near the top portion3380. The recessed portion 3410 may be defined by an upper wall 3412 ofthe back portion 3370 and a ledge portion 3414. The upper wall 3412 ofthe back portion 3370 may extend from a location at or near thehorizontal midplane 4120 to a location at or near the top portion 3380.The ledge portion 3414 may extend from the upper wall 3412 of the backportion 3370 to a lower wall 3416 of the back portion 3370. The lowerwall 3416 of the back portion 3370 may extend from a location at or nearthe horizontal midplane 4120 to a location at or near the bottom portion3380. The ledge portion 3414 may extends from the upper wall 3412 in adirection away from the face portion 3360. Accordingly, the ledgeportion 3414 facilitates a transition from the upper wall 3412 to thelower wall 3416 by which the width of the body portion 3310 issubstantially increased at or near the horizontal midplane 4120 ascompared to the width of the body portion 3310 above the horizontalmidplane. The ledge portion 3414 may have a ledge portion width 3418(shown in FIG. 39) that is greater than an upper body width 3420 of thebody portion 3310. In one example, the ledge portion width 3418 may bedefined as a width of a surface on the back portion 3370 that extendsbetween a plane 3413 generally defining the upper wall 3412 of the backportion 3370 and a plane 3417 generally defining the lower wall 3416 ofthe back portion 3370. The upper body width 3420 may be defined as awidth of the body portion 3310 at or above the horizontal midplane 4120.According to one example, the ledge portion width 3418 may be wider thanthe upper body width 3420 by a factor of between about 0.5 to about 1.0.According to another example, the ledge portion width 3418 may be widerthan the upper body width 3420 by a factor of about 1.5. According toanother example, the ledge portion width 3418 may be wider than theupper body width 3420 by a factor of about 3.0. Accordingly, a golf clubaccording to the examples described herein may have a ledge portionwidth 3418 that is wider than the upper body width 3420 by a factor ofgreater than or equal to about 0.5 to less than or equal to about 3.0.Accordingly, the body width 3990 at, near or below the horizontalmidplane 4120 may be substantially greater than the upper body width3420, which may provide for a cavity width 3840 that may be around 20%to 80% of the body width 3990 at, near or below the horizontal midplane4120. Further, the recessed portion 3410 allows the golf club head 3300to generally have a greater mass below the horizontal midplane 4120 thanabove the horizontal plane 4120. In other words, the mass that isremoved from the golf club head 3300 to define the recessed portion 3410may be moved to aft or back portions of the body portion 3310 that arearound and below the horizontal midplane 4120.

To generally maintain a cavity width 3840 that may be around 20%-80% ofthe body width 3990, the cavity width 3840 may be greater near the soleportion 3390 or below the horizontal midplane 4120 than near the topportion 3380 or above the horizontal midplane 4120. According to oneexample, the cavity width 3840 may generally vary according to avariation in the body width 3990 at certain regions of the body portion3310 between the top portion 3380 and the sole portion 3390 and betweenthe toe portion 3340 and the heel portion 3350. For example, as shown inFIG. 40, the cavity width 3840 may generally vary according to the bodywidth 3990 in certain regions of the body portion 3310 between the topportion 3380 and the sole portion 3390. The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

In one example, the interior cavity 3800 may be unfilled (i.e., emptyspace). The body portion 3300 with the interior cavity 3800 may weightabout 100 grams less than the body portion 3300 without the interiorcavity 3800. Alternatively, the interior cavity 3800 may be partially orentirely filled with an elastic polymer or elastomer material (e.g., aviscoelastic urethane polymer material such as Sorbothane® materialmanufactured by Sorbothane, Inc., Kent, Ohio), a thermoplastic elastomermaterial (TPE), a thermoplastic polyurethane material (TPU), and/orother suitable types of materials to absorb shock, isolate vibration,and/or dampen noise. For example, at least 50% of the interior cavity3800 may be filled with a TPE material to absorb shock, isolatevibration, and/or dampen noise when the golf club head 3300 strikes agolf ball via the face portion 3362.

In another example, the interior cavity 3800 may be partially orentirely filled with a polymer material such as an ethylene copolymermaterial to absorb shock, isolate vibration, and/or dampen noise whenthe golf club head 3300 strikes a golf ball via the face portion 3362.In particular, at least 50% of the interior cavity 3800 may be filledwith a high density ethylene copolymer ionomer, a fatty acid modifiedethylene copolymer ionomer, a highly amorphous ethylene copolymerionomer, an ionomer of ethylene acid acrylate terpolymer, an ethylenecopolymer comprising a magnesium ionomer, an injection moldable ethylenecopolymer that may be used in conventional injection molding equipmentto create various shapes, an ethylene copolymer that can be used inconventional extrusion equipment to create various shapes, and/or anethylene copolymer having high compression and low resilience similar tothermoset polybutadiene rubbers. For example, the ethylene copolymer mayinclude any of the ethylene copolymers associated with DuPont™High-Performance Resin (HPF) family of materials (e.g., DuPont™ HPFAD1172, DuPont™ HPF AD1035, DuPont® HPF 1000 and DuPont™ HPF 2000),which are manufactured by E.I. du Pont de Nemours and Company ofWilmington, Del. The DuPont™ HPF family of ethylene copolymers areinjection moldable and may be used with conventional injection moldingequipment and molds, provide low compression, and provide highresilience. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

As described herein, the cavity width 3840 may vary between about20%-80% of a body width 3990 at or below the horizontal midplane 4120.According to one example, at least 50% of the elastic polymer orelastomer material partially or filling the interior cavity 3800 may belocated below the horizontal midplane 4120 of the golf club head 3300.Accordingly, the center of gravity of the golf club head 3300 may befurther lowered and moved farther back as compared to a golf club headwith a cavity width of less than about 20% of the body width and that ispartially or fully filled with an elastic polymer or elastomer material.Further, the golf club head 3300 may produce relatively more consistentfeel, sound, and/or result when the golf club head 3300 strikes a golfball via the face portion 3362 as compared to a golf club head with acavity width of less than about 20% of the body width that is partiallyor fully filled with an elastic polymer material.

The thickness of the face portion 3362 may vary between the top portion3380 and the sole portion and between the toe portion 3340 and the heelportion as discussed in detail herein and shown in the examples of FIGS.15 and 16. According, a detailed description of the variation in thethickness of the face portion 3362 is not provided. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

Different from other golf club head designs, the interior cavity 3800 ofthe body portion 3310 and the location of the first and second sets ofweight portions 3320 and 3330, respectively, along the perimeter of thegolf club head 3300 may result in a golf ball traveling away from theface portion 3362 at a relatively higher ball launch angle and arelatively lower spin rate. As a result, the golf ball may travelfarther (i.e., greater total distance, which includes carry and rolldistances).

The golf club head 3300 may be manufactured by any of the methodsdescribed herein and illustrated in FIG. 17. Accordingly, a detaileddescription of the method of manufacturing the golf club head 3300 isnot provided.

As illustrated in FIGS. 37 and 41, for example, the golf club head 3300may include one or more weight ports (e.g., one shown as weight ports3521 and 3531) that may open to the to the cavity 3800. The weight port3531 may include a first opening 3930 and a second opening 3935. Thesecond opening 3935 may be used to access the interior cavity 3800. Inone example, the process 1700 (FIG. 17) may fill the interior cavity3800 with an elastic polymer material by injecting the elastic polymermaterial into the interior cavity 3800 from the first opening 3930 viathe second opening 3935. The first and second openings 3930 and 3935,respectively, may be same or different in size and/or shape. The weightport 3521 may include a first opening 4030 and a second opening 4035.The second opening 4035 may be used to access the interior cavity 3800.In one example, the process 1700 (FIG. 17) may fill the interior cavity3800 with an elastic polymer material by injecting the elastic polymermaterial into the interior cavity 3800 from the weight port 3531. As theelastic polymer fills the interior cavity 3800, the air inside theinterior cavity 3800 that is displaced by the elastic polymer materialmay exit the interior cavity from the weight port 3521 through thesecond opening 4035 and then the first opening 4030. After the cavity ispartially or fully filled with the elastic polymer material, the weightports 3531 and 3521 may be closed by inserting and securing weightportions therein as described in detail herein. Alternatively, theelastic polymer material may be injected into the interior cavity 3800from the weight port 3521. Accordingly, the weight port 3531 mayfunction as an exit port for the displaced air inside the interiorcavity 3800. While the above example may describe and depict particularweight ports with second openings, any other weight ports of the golfclub head 4200 may include a second opening (e.g., the weight port3532). The apparatus, methods, and articles of manufacture describedherein are not limited in this regard.

FIG. 43 depicts one manner by which the interior cavity 700 of the golfclub head 100 or any of the golf club heads described herein may bepartially or entirely filled with an elastic polymer material or anelastomer material (e.g., an elastic polymer material 2820 of FIG. 28such as a TPE material). The process 4300 may begin with bonding abonding agent to the back surface 166 of the face portion 162 of thegolf club head 100 (block 4310). The bonding agent may have an initialbonding state, which may be a temporary bonding state, and a finalbonding state, which may be a permanent bonding state. The initialbonding state and the final bonding states may be activated when thebonding agent is exposed to heat, radiation, and/or other chemicalcompounds. For example, as described in detail herein, the bonding agentmay be an epoxy having an initial cure state and a final cure state thatare activated by the epoxy being heated to different temperatures for aperiod of time, respectively, by conduction, convention and/orradiation. In another example, the bonding agent may be a bondingmaterial that is activated to an initial bonding state and a finalbonding state by being exposed to different doses and/or duration ofultraviolet radiation, respectively. In another example, the bondingagent may be a bonding material that is activated to an initial bondingstate and a final bonding state by being exposed to different compoundsor different amounts of the same compound, respectively. According tothe process 4300, the bonding agent may be bonded to the back surface ofthe face portion by being activated to the initial bonding state.Elastic polymer material is then injected in the interior cavity 700 ofthe golf club head 100 (block 4320). The process 4300 then includesbonding the elastic polymer material to the bonding agent (block 4330).Bonding the elastic polymer material to the bonding agent includesactivating the bonding agent to the final bonding state to permanentlybond the elastic polymer material to the bonding agent and topermanently bond the bonding agent to the back surface 166 of the faceportion 162. The example process 4300 is merely provided and describedin conjunction with other figures as an example of one way tomanufacture the golf club head 100. While a particular order of actionsis illustrated in FIG. 43, these actions may be performed in othertemporal sequences. Further, two or more actions depicted in FIG. 43 maybe performed sequentially, concurrently, or simultaneously.

FIG. 44 depicts one manner by which the interior cavity 700 of the golfclub head 100 or any of the golf club heads described herein may bepartially or entirely filled with an elastic polymer material or anelastomer material (e.g., an elastic polymer material 2820 of FIG. 28such as a TPE material). The process 4400 may begin with applying abonding agent (e.g., a bonding portion 2810 of FIG. 28) to the backsurface 166 of the face portion 162 of the golf club head 100 (block4410). The bonding agent may be any type of adhesive and/or othersuitable materials. In one example, the bonding agent may be an epoxy.Prior to applying the bonding agent, the golf club head 100 may becleaned to remove any oils, other chemicals, debris or other unintendedmaterials from the golf club head 100 (not shown). The bonding agent maybe applied on the back surface 166 as described herein depending on theproperties of the bonding agent. The bonding agent may be applied to theback surface 166 of the face portion 162 through one or more of thefirst set of weight ports 1420 and/or the second set of weight ports1430. For example, the bonding agent may be in liquid form and injectedon the back surface 166 through several or all of the first set ofweight ports 1420 and the second set of weight ports 1430. An injectioninstrument (not shown) such as a nozzle or a needle may be inserted intoeach weight port until the tip or outlet of the injection instrument isnear the back surface 166. The bonding agent may then be injected on theback surface 166 from the outlet of the injection instrument.Additionally, the injection instrument may be moved, rotated and/orswiveled while inside the interior cavity 700 so that the bonding agentmay be injected onto an area of the back surface 166 surrounding theinjection instrument. For example, the outlet of the injectioninstrument may be moved in a circular pattern while inside a weight portto inject the bonding agent in a corresponding circular pattern on theback surface 166. Each of the first set of weight ports 1420 and thesecond set of weight ports 1430 may be utilized to inject a bondingagent on the back surface 166. However, utilizing all of first weightports 1420 and/or the second set of weight ports 1430 may not benecessary. For example, using every other adjacent weight port may besufficient to inject a bonding agent on the entire back surface 166. Inanother example, weight ports 1421, 1422 1431, 1433 and 1436 may be usedto inject the bonding agent on the back surface 166. The apparatus,methods, and articles of manufacture are not limited in this regard.

The process 4400 may also include spreading or overlaying the bondingagent on the back surface 166 (not shown) after injecting the bondingagent onto the back surface 166 so that a generally uniform coating ofthe bonding agent is provided on the back surface 166. According to oneexample, the bonding agent may be spread on the back surface 166 byinjecting air into the interior cavity 700 through one or more of thefirst set of weight ports 1420 and/or the second set of weight ports1430. The air may be injected into the interior cavity 700 and on theback surface 166 by inserting an air nozzle into one or more of thefirst set of weight ports 1420 and/or the second set of weight ports1430. According to one example, the air nozzle may be moved, rotatedand/or swiveled at a certain distance from the back surface 166 so as touniformly blow air onto the bonding agent to spread the bonding agent onthe back surface 166 for a uniform coating or a substantially uniformcoating of the bonding agent on the back surface 166. In one example,the golf club head 100 may be pivoted back and forth in one or severaldirections so that the bonding agent is spread along a portion orsubstantially the entire area of the back surface 166 of the faceportion 162. In one example, the golf club head 100 may be vibrated withthe back surface 166 of the face portion 162 in a generally horizontalorientation so that the bonding agent may spread or overlay on the backsurface 166 in a uniform coating manner or a substantially uniformcoating manner. The apparatus, methods, and articles of manufacture arenot limited in this regard.

The example process 4400 is merely provided and described in conjunctionwith other figures as an example of one way to manufacture the golf clubhead 100. While a particular order of actions is illustrated in FIG. 44,these actions may be performed in other temporal sequences. Further, twoor more actions depicted in FIG. 44 may be performed sequentially,concurrently, or simultaneously. The process 4400 may include a singleaction (not shown) of injecting and uniformly or substantially uniformlycoating the back surface 166 with the bonding agent. In one example, thebonding agent may be injected on the back surface 166 by being convertedinto fine particles or droplets (i.e., atomized) and sprayed on the backsurface 166. Accordingly, the back surface 166 may be uniformly orsubstantially uniformly coated with the bonding agent in one action. Asubstantially uniform coating of the bonding agent on the back surface166 may be defined as a coating having slight non-uniformities due tothe injection process or the manufacturing process. However, such slightnon-uniformities may not affect the bonding of the elastic polymermaterial or elastomer material to the back surface 166 with the bondingagent as described herein. For example, spraying the bonding agent onthe back surface 166 may result in overlapping regions of the bondingagent having a slightly greater coating thickness than other regions ofthe bonding agent on the back surface 166. The apparatus, methods, andarticles of manufacture are not limited in this regard.

In one example as shown in FIG. 45, the bonding agent may be an epoxyhaving different curing states based on the temperature and the amountof time to which the epoxy may be exposed. The bonding agent may have anuncured state, an initial cure state, and a final cure state. In oneexample, the uncured state may be a liquid state, the initial cure statemay be gel or a semi-solid/semi-liquid state, and the final cure statemay be a solid state. The bonding agent may transition from the uncuredstate to the initial cure state when the bonding agent is heated to atemperature between an initial cure state temperature (Temp_(i)) and afinal cure state temperature (Temp_(f)) for a period of time.Accordingly, an initial cure state temperature range may be defined bytemperatures that are greater than or equal to the initial cure statetemperature Temp_(i) and less than the final cure state temperatureTemp_(f). The bonding agent may transition from the initial cure stateto the final cure state when the bonding agent may be heated to atemperature greater than or equal to the final cure state temperatureTemp_(f) for a period of time. Accordingly, a final cure statetemperature range may be defined by temperatures that are greater thanor equal to the final cure state temperature Temp_(f). As shown in FIG.45, the initial cure state temperature Temp_(i) and the final cure statetemperature Temp_(f) may vary based on the amount of time that thebonding agent may be heated. In particular, a transition from theuncured state to the initial cure state and a transition from theinitial cure state to the final cure state may be dictated by certaintemperature and time profiles based on the properties of the bondingagent. At a temperature below the initial cure temperature Temp_(i), thebonding agent may be in the uncured state (e.g., a liquid state). In theinitial cure state, the bonding agent may form an initial bond with anobject and become pliable to be manipulated (e.g., moved, spread,overlay, etc.) without obtaining full cross linking or forming apermanent bond. In other words, the bonding agent may form an initialbond with an object and be manipulated without forming a permanent bond.In the final cure state, the bond of the bonding agent (e.g., crosslinking for a bonding agent that includes epoxy) may be complete orbecome permanently set.

The bonding agent may be applied to the back surface 166 of the faceportion 162 when the bonding agent is in the uncured state, which may bea liquid state. Subsequently, the golf club head 100 and/or the bondingagent may be heated to a first temperature Temp₁ that is greater than orequal to the initial cure state temperature Temp_(i) and less than thefinal cure state temperature Temp_(f) to change the bonding agent froman uncured state to an initial cure state (i.e., an initial cure statetemperature range) (block 4420). Accordingly, the bonding agent may forman initial bond with the back surface 166 of the face portion 162. Afterbonding the bonding agent to the back surface 166, the golf club headmay be cooled for a period of time at ambient or room temperature (notshown). Accordingly, the bonding agent may be in an initial cured stateand bonded to the back surface 166 of the face portion 162 so that thebonding agent may be bonded to the back surface 166 during the injectionmolding of an elastic polymer material in the interior cavity 700.Ambient or room temperature may be defined as a room temperature rangingbetween 5° C. (41° F.) to 40° C. (104° F.). The first temperature Temp₁and duration by which the golf club head and/or the bonding agent heatedto the first temperature Temp₁ may depend on the curing or bondingproperties of the bonding agent. The apparatus, methods, and articles ofmanufacture are not limited in this regard.

After the bonding agent is bonded to the back surface 166 of the faceportion 162, the golf club head 100 may be heated (i.e., pre-heating thegolf club head 100) prior to receiving the elastic polymer material (notshown). The golf club head 100 may be heated so that when the elasticpolymer material is injected in the golf club head 100, the elasticpolymer material is not cooled by contact with the golf club head andremains in a flowing liquid form to fill the internal cavity 700. Thetemperature to which the golf club head is heated, which may be referredto herein as a third temperature, may be similar to the temperature ofthe elastic polymer material when being injected into the internalcavity 700. However, the temperature to which the golf club head isheated may be less than the final cure temperature Temp_(f) of thebonding agent. Accordingly, the bonding agent may not transition fromthe initial cure state to the final cured state during the injectionmolding process. Further, the pre-heating temperature of the golf clubhead 100 may be determined so that excessive cooling of the golf clubhead 100 may not be necessary after injection molding the elasticpolymer material in the internal cavity 700. Prior to being injectedinto the internal cavity 700, the elastic polymer material may also beheated to a liquid state (not shown). The temperature to which theelastic polymer material may be heated may depend on the type of elasticpolymer material used to partially or fully fill the interior cavity700. Further, the temperature to which the elastic polymer material isheated may be determined so that shrinkage of the elastic polymermaterial is reduced during the injection molding process. However, asdescribed herein, the elastic polymer material may be heated to atemperature that is less than the final cure temperature Temp_(f) of thebonding agent. The apparatus, methods, and articles of manufacture arenot limited in this regard.

As described herein, the cavity 700 may be partially or fully filledwith the elastic polymer material by injecting the elastic polymermaterial in the cavity 700 (block 4430). The injection speed of theelastic polymer material may be determined so that the interior cavity700 may be slowly filled to provide a better fill while allowing air toescape the interior cavity 700 and allowing the injected elastic polymermaterial to rapidly cool. For example, the elastic polymer material maybe a non-foaming and injection-moldable thermoplastic elastomer (TPE)material. The elastic polymer material may be injected into the interiorcavity 700 from one or more of the weight ports described herein (e.g.,one or more weight ports of the first and second sets of weight ports1420 and 1430, respectively, shown in FIG. 14). One or more other weightports may allow the air inside the interior cavity 700 displaced by theelastic polymer material to vent from the interior cavity 700. In oneexample, the golf club head 100 may be oriented horizontally as shown inFIG. 14 during the injection molding process. The elastic polymermaterial may be injected into the interior cavity 700 from weight ports1431 and 1432. The weight ports 1421, 1422 and/or 1423 may serve as airports for venting the displaced air from the interior cavity 700. Thus,regardless of the orientation of the golf club head 100 during theinjection molding process, the elastic polymer material may be injectedinto the interior cavity 700 from one or more lower positioned weightports while one or more upper positioned weight ports may serve as airvents.

According to one example, any one of the weight ports or any air vent onthe golf club head 100 that may be used as air ports for venting thedisplaced air may be connected to a vacuum source (not shown) during theinjection molding process. Accordingly, air inside the interior cavity700 and displaced by the elastic polymer material may be removed fromthe interior cavity 700 by the vacuum source. Thus, a possibility ofhaving trapped air pockets in the interior cavity 700 and/or anon-uniform filling of the interior cavity 700 with the elastic polymermaterial may be reduced. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

After the elastic polymer material is injected in the cavity 700, thegolf club head 100 may be heated to a second temperature Temp₂ that isgreater than or equal to the final cure temperature Temp_(f) of thebonding agent to reactivate the bonding agent to bond the elasticpolymer material to the bonding agent (i.e., a final cure statetemperature range) (block 4440). The second temperature Temp₂ and theduration by which the golf club head 100 is heated to the secondtemperature Temp₂ may depend on the properties of the bonding agent asshown in FIG. 45 to form a permanent bond between the golf club head 100and the bonding agent and between the elastic polymer material and thebonding agent. The golf club head 100 may be then cooled at ambient orroom temperature (not shown). According to one example, thecharacteristic time (CT) of the golf club head may be measured (notshown) after manufacturing the golf club head as discussed herein. CTmeasurements may determine if the golf club head conforms to CT rulesestablished by one or more golf governing bodies.

The heating and cooling processes described herein may be performed byconduction, convention, and/or radiation. For example, all of theheating and cooling processes may be performed by using heating orcooling systems that employ conveyor belts that move the golf club head100 through a heating or cooling environment for a period of time asdiscussed herein. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

An elastic polymer material with a low modulus of elasticity, such as afoaming elastic polymer material, may provide vibration and noisedampening for the face portion 162 when the face portion 162 impacts agolf ball. An elastic polymer material with a higher modulus ofelasticity, such as a non-foaming elastic polymer material, may providestructural support to the face portion 162 in addition to providingvibration and noise dampening. Accordingly, a thin face portion 162 maybe provided when the interior cavity 700 is filled with a non-foamingelastic polymer material since the elastic polymer material may providestructural support to the thin face portion 162. In one example, theelastic polymer material that is injection molded in the interior cavity700 may have a relatively high modulus of elasticity to providestructural support to the face portion 162 and yet elastically deflectto absorb the impact forces experienced by the face portion 162 whenstriking a golf ball. Thus, a non-foaming and injection moldable elasticpolymer material with a relatively high modulus of elasticity may beused for partially or fully filling the interior cavity 700 to providestructural support and reinforcement for the face portion 162 inaddition to providing vibration and noise dampening. That is, thenon-foaming and injection moldable elastic polymer material may be astructural support portion for the face portion 162. The apparatus,methods, and articles of manufacture are not limited in this regard.

While the above examples may described an iron-type or a wedge-type golfclub head, the apparatus, methods, and articles of manufacture describedherein may be applicable to other types of golf club heads.

The terms “and” and “or” may have both conjunctive and disjunctivemeanings. The terms “a” and “an” are defined as one or more unless thisdisclosure indicates otherwise. The term “coupled” and any variationthereof refer to directly or indirectly connecting two or more elementschemically, mechanically, and/or otherwise. The phrase “removablyconnected” is defined such that two elements that are “removablyconnected” may be separated from each other without breaking ordestroying the utility of either element.

The term “substantially” when used to describe a characteristic,parameter, property, or value of an element may represent deviations orvariations that do not diminish the characteristic, parameter, property,or value that the element may be intended to provide. Deviations orvariations in a characteristic, parameter, property, or value of anelement may be based on, for example, tolerances, measurement errors,measurement accuracy limitations and other factors. The term “proximate”is synonymous with terms such as “adjacent,” “close,” “immediate,”“nearby”, “neighboring”, etc., and such terms may be usedinterchangeably as appearing in this disclosure.

The apparatus, methods, and articles of manufacture described herein maybe implemented in a variety of embodiments, and the foregoingdescription of some of these embodiments does not necessarily representa complete description of all possible embodiments. Instead, thedescription of the drawings, and the drawings themselves, disclose atleast one embodiment, and may disclosure alternative embodiments.

As the rules of golf may change from time to time (e.g., new regulationsmay be adopted or old rules may be eliminated or modified by golfstandard organizations and/or governing bodies such as the United StatesGolf Association (USGA), the Royal and Ancient Golf Club of St. Andrews(R&A), etc.), golf equipment related to the apparatus, methods, andarticles of manufacture described herein may be conforming ornon-conforming to the rules of golf at any particular time. Accordingly,golf equipment related to the apparatus, methods, and articles ofmanufacture described herein may be advertised, offered for sale, and/orsold as conforming or non-conforming golf equipment. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

Although certain example apparatus, methods, and articles of manufacturehave been described herein, the scope of coverage of this disclosure isnot limited thereto. On the contrary, this disclosure covers allapparatus, methods, and articles of articles of manufacture fairlyfalling within the scope of the appended claims either literally orunder the doctrine of equivalents.

What is claimed is:
 1. A golf club head comprising: a body portionhaving a toe portion, a heel portion, a top portion, a sole portion, aback portion with a plurality of weight portions, and a front portionhaving a face portion with a thickness extending between a front surfaceand a back surface, the thickness being less than or equal to 1.5millimeters (0.06 inch); an interior cavity extending between the topand sole portions and between the face and back portions; a bondingportion bonded to the back surface of the face portion; and an elasticpolymer material injection molded in the interior cavity to structurallysupport the face portion during impact with a golf ball, wherein theelastic polymer material is bonded to the bonding portion; wherein agreater number of weight portions of the plurality of weight portionsare located on the back portion below a horizontal midplane of the bodyportion than above the horizontal midplane.
 2. A golf club head asdefined in claim 1, wherein the bonding portion comprises a bondingagent having a first cure state within a first temperature range and asecond cure state within a second temperature range different from thefirst temperature range, wherein the bonding portion is bonded to theback surface of the face portion in the first cure state of the bondingagent, and wherein the elastic polymer material is bonded to the bondingportion in the second cure state of the bonding agent.
 3. A golf clubhead as defined in claim 1, wherein the back portion comprises aplurality of exterior ports, and wherein each exterior port of theplurality of exterior ports is configured to receive a weight portion ofthe plurality of weight portions.
 4. A golf club head as defined inclaim 1, wherein the bonding portion is bonded to the back surface ofthe face portion before the elastic polymer material is bonded to thebonding portion.
 5. A golf club head as defined in claim 1, wherein theelastic polymer material comprises at least one of a thermoplasticelastomer material or a thermoplastic polyurethane material.
 6. A golfclub head as defined in claim 1, wherein the bonding portion comprises auniform coating or a substantially uniform coating of a bonding agent onthe back surface of the face portion.
 7. A golf club head as defined inclaim 1, wherein the face portion comprises a substantially uniformthickness from at or proximate to the top portion to at or proximate tothe sole portion.
 8. A golf club head comprising: a body portion havinga toe portion, a heel portion, a top portion, a sole portion, a backportion with a plurality of weight portions, and a front portion havinga face portion with a front surface and a back surface; an interiorcavity extending between the top and sole portions and between the faceand back portions; a bonding portion bonded to the back surface of theface portion; an elastic polymer material injection molded in theinterior cavity to structurally support the face portion during impactwith a golf ball; wherein the bonding portion is bonded to the faceportion before injection molding the elastic polymer material in theinterior cavity; wherein the elastic polymer material is bonded to thebonding portion after being injection molded in the interior cavity, andwherein a greater number of weight portions of the plurality of weightportions are located on the back portion below a horizontal midplane ofthe body portion than above the horizontal midplane.
 9. A golf club headas defined in claim 8, wherein the bonding portion is bonded to the faceportion at a first temperature, and wherein the elastic polymer materialis bonded to the bonding portion at a second temperature higher than thefirst temperature.
 10. A golf club head as defined in claim 8, whereinthe bonding portion comprises a bonding agent, wherein the bondingportion is bonded to the face portion at a temperature within an initialcure state temperature range of the bonding agent, and wherein theelastic polymer material is bonded to the bonding portion at atemperature within a final cure state temperature range of the bondingagent.
 11. A golf club head as defined in claim 8, wherein the backportion comprises a plurality of exterior ports, and wherein eachexterior port of the plurality of exterior ports is configured toreceive a weight portion of the plurality of weight portions.
 12. A golfclub head as defined in claim 8, wherein the elastic polymer materialcomprises at least one of a thermoplastic elastomer material or athermoplastic polyurethane material.
 13. A golf club head as defined inclaim 8, wherein the face portion comprises a thickness extendingbetween the front and back surfaces of less than or equal to1.5millimeters (0.06 inch).
 14. A golf club head as defined in claim 8,wherein the face portion comprises a substantially uniform thicknessfrom at or proximate to the top portion to at or proximate to the soleportion, and wherein the substantially uniform thickness extends lessthan or equal to 1.5 millimeters (0.06 inch) between the front and backsurfaces.
 15. A golf club head as defined in claim 8, wherein thebonding portion comprises a uniform coating or a substantially uniformcoating of a bonding agent on the back surface of the face portion. 16.A golf club head comprising: a body portion having a toe portion, a heelportion, a top portion, a sole portion, a back portion with a pluralityof weight portions, and a front portion having a face portion with afront surface and a back surface, a thickness of the face portionextending between the front and back surfaces being less than or equalto 1.5 millimeters (0.06 inch); an interior cavity extending between thetop and sole portions and between the face and back portions; a bondingportion having an initial cure state and a final cure state with adifferent bonding configuration than the initial cure state, the bondingportion configured to bond to the back surface of the face portion atthe initial cure state; and an elastic polymer material injection moldedin the interior cavity to structurally support the face portion duringimpact with a golf ball, the bonding portion configured to bond to theelastic polymer material at the final cure state, wherein a greaternumber of weight portions of the plurality of weight portions are closerto the toe portion than the heel portion.
 17. A golf club head asdefined in claim 16, wherein the initial cure state of the bondingportion is activated at a first temperature within an initial cure statetemperature range of the bonding portion, wherein the final cure stateof the bonding portion is activated at a second temperature within afinal cure state temperature range of the bonding portion, and whereinthe second temperature is greater than the first temperature.
 18. A golfclub head as defined in claim 16, wherein the elastic polymer materialcomprises at least one of a thermoplastic elastomer material or athermoplastic polyurethane material.
 19. A golf club head as defined inclaim 16, wherein a greater number of weight portions of the pluralityof weight portions are located on the back portion below a horizontalmidplane of the body portion than above the horizontal midplane.
 20. Agolf club head as defined in claim 16, wherein the face portioncomprises a substantially uniform thickness from at or proximate to thetop portion to at or proximate to the sole portion.